Konica Minolta 2400w 2430 Dl Sm 2

SERVICE MANUAL THEORY OF OPERATION
magicolor® 2430 DL
magicolor® 2400W
magicolor 2400W
®
magicolor 2430 DL
®
THEORY OF OPERATION
2004.10 Ver.2.0
© 2004 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

Printed in Japan
Use of this manual should be strictly supervised to
4139-7990-11
2004.10
avoid disclosure of confidential information.
0410XXXX Ver. 2.0
SAFETY AND IMPORTANT WARNING ITEMS

Read carefully the Safety and Important Warning Items described below to understand
them before doing service work.
IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this product as well as
the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
(hereafter called the KMBT) strongly recommends that all servicing be performed only by
KMBT-trained service technicians.
Changes may have been made to this product to improve its performance after this Service
Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that
the information contained in this Service Manual is complete and accurate.
The user of this Service Manual must assume all risks of personal injury and/or damage to
the product while servicing the product for which this Service Manual is intended.
Therefore, this Service Manual must be carefully read before doing service work both in the
course of technical training and even after that, for performing maintenance and control of
the product properly.
Keep this Service Manual also for future service.
DESCRIPTION ITEMS FOR DANGER,

WARNING AND CAUTION
In this Service Manual, each of three expressions “ DANGER”, “ WARNING”, and
“ CAUTION” is defined as follows together with a symbol mark to be used in a limited
meaning.
When servicing the product, the relevant works (disassembling, reassembling, adjustment,
repair, maintenance, etc.) need to be conducted with utmost care.
DANGER: Action having a high possibility of suffering death or serious injury
WARNING: Action having a possibility of suffering death or serious injury
CAUTION: Action having a possibility of suffering a slight wound, medium

trouble, and property damage
Symbols used for safety and important warning items are defined as follows:
:Precaution when servicing the

product. General Electric hazard High temperature
precaution
:Prohibition when servicing the

product. General Do not touch Do not
prohibition with wet hand disassemble
:Direction when servicing the

product. General Unplug Ground/Earth
instruction
S-1
SAFETY WARNINGS
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA
BUSINESS TECHNOLOGIES, INC.
KONICA MINOLTA brand products are renowned for their high reliability. This reliability is
achieved through high-quality design and a solid service network.
Product design is a highly complicated and delicate process where numerous mechanical,
physical, and electrical aspects have to be taken into consideration, with the aim of arriving
at proper tolerances and safety factors. For this reason, unauthorized modifications involve
a high risk of degradation in performance and safety. Such modifications are therefore
strictly prohibited. the points listed below are not exhaustive, but they illustrate the reason-
ing behind this policy.
Prohibited Actions
DANGER
• Using any cables or power cord not specified by KMBT.
• Using any fuse or thermostat not specified by KMBT.

Safety will not be assured, leading to a risk of fire and
injury.
• Disabling fuse functions or bridging fuse terminals with

wire, metal clips, solder or similar object.
• Disabling relay functions (such as wedging paper between

relay contacts)
• Disabling safety functions (interlocks, safety circuits, etc.)

Safety will not be assured, leading to a risk of fire and
injury.
• Making any modification to the product unless instructed

by KMBT
• Using parts not specified by KMBT
S-2
[2] POWER PLUG SELECTION

In some countries or areas, the power plug provided with the product may not fit wall outlet
used in the area. In that case, it is obligation of customer engineer (hereafter called the CE)
to attach appropriate power plug or power cord set in order to connect the product to the
supply.
Power Cord Set or Power Plug
WARNING
• Use power supply cord set which meets the following
criteria:
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the prod-
kw
uct's rated voltage and current, and
- the plug has pin/terminal(s) for grounding, and
- provided with three-conductor cable having enough cur-
rent capacity, and
- the cord set meets regulatory requirements for the area.
Use of inadequate cord set leads to fire or electric shock.
• Attach power plug which meets the following criteria:

- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- the plug has pin/terminal(s) for grounding, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connect-
ing to inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
• Conductors in the power cable must be connected to ter-

minals of the plug according to the following order:
• Black or Brown: L (line)
• White or Light Blue: N (neutral)
• Green/Yellow: PE (earth)
Wrong connection may cancel safeguards within the
product, and results in fire or electric shock.
S-3
[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

KONICA MINOLTA brand products are extensively tested before shipping, to ensure that all
applicable safety standards are met, in order to protect the customer and customer engi-
neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical
equipment may be subject to parts wear and eventual failure. In order to maintain safety
and reliability, the CE must perform regular safety checks.
1. Power Supply
Connection to Power Supply
WARNING
• Check that mains voltage is as specified.
Connection to wrong voltage supply may result in fire or
electric shock.
• Connect power plug directly into wall outlet having same
configuration as the plug.
Use of an adapter leads to the product connecting to kw
inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
If proper wall outlet is not available, advice the customer
to contact qualified electrician for the installation.
• Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.
• If two or more power cords can be plugged into the wall
outlet, the total load must not exceed the rating of the wall
outlet.
If excessive current flows in the wall outlet, fire may
result.
• Make sure the power cord is plugged in the wall outlet

securely.
Contact problems may lead to increased resistance,
overheating, and the risk of fire.
• Check whether the product is grounded properly.

If current leakage occurs in an ungrounded product, you
may suffer electric shock while operating the product.
Connect power plug to grounded wall outlet.
S-4
Power Plug and Cord
WARNING
• When using the power cord set (inlet type) that came with
this product, make sure the connector is securely inserted
in the inlet of the product.
When securing measure is provided, secure the cord with
the fixture properly.
If the power cord (inlet type) is not connected to the prod-
uct securely, a contact problem may lead to increased
resistance, overheating, and risk of fire.
• Check whether the power cord is not stepped on or

pinched by a table and so on.
Overheating may occur there, leading to a risk of fire.
• Check whether the power cord is damaged. Check

whether the sheath is damaged.
If the power plug, cord, or sheath is damaged, replace
with a new power cord (with plug and connector on each
end) specified by KMBT. Using the damaged power cord
may result in fire or electric shock.
• Do not bundle or tie the power cord.
Overheating may occur there, leading to a risk of fire.
• Check whether dust is collected around the power plug

and wall outlet.
Using the power plug and wall outlet without removing
dust may result in fire.
• Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.
• When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.
S-5
Wiring
WARNING
• Never use multi-plug adapters to plug multiple power cords
in the same outlet.
If used, the risk of fire exists.
• When an extension cord is required, use a specified one.

Current that can flow in the extension cord is limited, so
using a too long extension cord may result in fire.
Do not use an extension cable reel with the cable taken
up. Fire may result.
2. Installation Requirements
Prohibited Installation Places
WARNING
• Do not place the product near flammable materials or vola-
tile materials that may catch fire.
A risk of fire exists.
• Do not place the product in a place exposed to water such

as rain.
A risk of fire and electric shock exists.
When not Using the Product for a long time
WARNING
• When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.
S-6
Ventilation
CAUTION
• The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
Stability
CAUTION
• Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
Inspection before Servicing
CAUTION
• Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure, using only the prescribed tools. Do not make any
adjustment not described in the documentation.
If the prescribed procedure or tool is not used, the prod-
uct may break and a risk of injury or fire exists.
• Before conducting an inspection, be sure to disconnect

the power plugs from the product and options.
When the power plug is inserted in the wall outlet, some
units are still powered even if the POWER switch is
turned OFF. A risk of electric shock exists.
• The area around the fixing unit is hot.
You may get burnt.
S-7
Work Performed with the Product Powered On
WARNING
• Take every care when making adjustments or performing
an operation check with the product powered.
If you make adjustments or perform an operation check
with the external cover detached, you may touch live or
high-voltage parts or you may be caught in moving gears
or the timing belt, leading to a risk of injury.
• Take every care when servicing with the external cover
detached.
High-voltage exists around the drum unit. A risk of elec-
tric shock exists.
Safety Checkpoints
WARNING
• Check the exterior and frame for edges, burrs, and other
damage.
The user or CE may be injured.
• Do not allow any metal parts such as clips, staples, and

screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
• Check wiring for squeezing and any other damage.

Current can leak, leading to a risk of electric shock or
fire.
• Carefully remove all toner remnants and dust from electri-
cal parts and electrode units such as a charging corona
unit.
Current can leak, leading to a risk of product trouble or
fire.
• Check high-voltage cables and sheaths for any damage.

fire.
S-8
Safety Checkpoints
WARNING
• Check electrode units such as a charging corona unit for
deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.
• Before disassembling or adjusting the write unit (P/H unit)

incorporating a laser, make sure that the power cord has
been disconnected.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
• Do not remove the cover of the write unit. Do not supply

power with the write unit shifted from the specified mount-
ing position.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
• When replacing a lithium battery, replace it with a new lith-

ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.
• After replacing a part to which AC voltage is applied (e.g.,

optical lamp and fixing lamp), be sure to check the installa-
tion state.
• Check the interlock switch and actuator for loosening and

check whether the interlock functions properly.
If the interlock does not function, you may receive an
electric shock or be injured when you insert your hand in
the product (e.g., for clearing paper jam).
• Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
fire.
S-9
Safety Checkpoints
WARNING
• Make sure that all screws, components, wiring, connec-
tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
Handling of Consumables
WARNING
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
• Never throw the used cartridge and toner into fire.

You may be burned due to dust explosion.
Handling of Service Materials
CAUTION
• Unplug the power cord from the wall outlet.
Drum cleaner (isopropyl alcohol) and roller cleaner (ace-
tone-based) are highly flammable and must be handled
with care. A risk of fire exists.
• Do not replace the cover or turn the product ON before

any solvent remnants on the cleaned parts have fully
evaporated.
S-10
Handling of Service Materials
CAUTION
• Use only a small amount of cleaner at a time and take
care not to spill any liquid. If this happens, immediately
wipe it off.
• When using any solvent, ventilate the room well.

Breathing large quantities of organic solvents can lead to
discomfort.
S-11
[4] Laser Safety

• This is a digital machine certified as a Class 1 laser product. There is no possibility of
danger from a laser, provided the machine is serviced according to the instruction in this
manual.
4.1 Internal Laser Radiation
semiconductor laser
Maximum power of the laser diode 10 mW
Maximum average radiation power (*) 7.5 µW
Wavelength 775-800 nm
*at laser aperture of the Print Head Unit
• This product employs a Class 3b laser diode that emits an invisible laser beam. The laser
diode and the scanning polygon mirror are incorporated in the print head unit.
• The print head unit is NOT A FIELD SERVICEABLE ITEM. Therefore, the print head unit
should not be opened under any circumstances.
Laser Aperture of
the Print Head Unit
This figure shows

the view inside the
Top Cover.
4139safe004c0
S-12
U.S.A., Canada
(CDRH Regulation)
• This machine is certified as a Class 1 Laser product under Radiation Performance Stan-
dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory
for Laser products marketed in the United States and is reported to the Center for
Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of
the U.S. Department of Health and Human Services (DHHS). This means that the device
does not produce hazardous laser radiation.
• The label shown on page S-16 indicates compliance with the CDRH regulations and
must be attached to laser products marketed in the United States.
.
CAUTION
• Use of controls, adjustments or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure.
semiconductor laser
All Areas
CAUTION
• Use of controls, adjustments or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure.
semiconductor laser
Denmark
ADVARSEL
• Usynlig laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion.
Undgå udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC60825-1
sikkerheds kravene.
halvlederlaser
Laserdiodens højeste styrke 10 mW
bølgelængden 775-800 nm
S-13
Finland, Sweden
LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
VAROITUS!
• Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat-
taa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle laser-
säteilylle.
puolijohdelaser
Laserdiodin suurin teho 10 mW
aallonpituus 775-800 nm
VARNING!
• Om apparaten används på annat sätt än i denna bruksanvisning specificerats,
kan användaren utsättas för osynlig laserstrålning, som överskrider gränsen
för laserklass 1.
halvledarlaser
Den maximala effekten för laserdioden 10 mW
våglängden 775-800 nm
VARO!
• Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättomälle laser-
säteilylle. Älä katso säteeseen.
VARNING!
• Osynlig laserstråining när denna del är öppnad och spärren är urkopplad.
Betrakta ej stråien.
Norway
ADVERSEL
• Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisn-
ing, kan brukeren utsettes för unsynlig laserstrålning, som overskrider grensen
for laser klass 1.
halvleder laser
Maksimal effekt till laserdiode 10 mW
bølgelengde 775-800 nm
S-14
4.2 Laser Safety Label

• A laser safety label is attached to the inside of the machine as shown below.
4139safe001c0
S-15
4.3 Laser Caution Label

• A laser caution label is attached to the outside of the machine as shown below.
A. magicolor 2400W
4139safe005e0
4139safe006e0
S-16
B. magicolor 2430 DL
4139safe007e0
4139safe008e0
S-17
4.4 PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT

• When laser protective goggles are to be used, select ones with a lens conforming to the
above specifications.
• When a disassembly job needs to be performed in the laser beam path, such as when
working around the printerhead and PC Drum, be sure first to turn the printer OFF.
• If the job requires that the printer be left ON, take off your watch and ring and wear laser
protective goggles.
• A highly reflective tool can be dangerous if it is brought into the laser beam path. Use
utmost care when handling tools on the user’s premises.
• The Print Head is not to be disassembled or adjusted in the field. Replace the Unit or
Assembly including the Control Board. Therefore, remove the Laser Diode, and do not
perform Control Board trimmer adjustment.
S-18
WARNING INDICATIONS ON THE MACHINE

Caution labels shown are attached in some areas on/in the machine.
When accessing these areas for maintenance, repair, or adjustment, special care should
be taken to avoid burns and electric shock.
or
or
High temperature
High voltage
4139safe009c0
S-19
High voltage
4139safe010c0
CAUTION:
• You may be burned or injured if you touch any area that you are advised not to
touch by any caution label. Do not remove caution labels. If any caution label has
come off or become dirty and therefore the caution cannot be read, contact our
Service Office.
S-20
®
magicolor 2400W
®
magicolor 2430 DL
Main Unit
2004.10
Ver. 2.0
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
• To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
2004/10 2.0 1 Adding the descriptions of magicolor 2430 DL

2004/09 1.0 — Issue of the first edition
Date Service manual Ver. Revision mark Descriptions of revision
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
CONTENTS
I General
1. System configuration............................................................................................ 1-1
2. Product specifications .......................................................................................... 1-2
2.1 Type ................................................................................................................... 1-2
I Outline
2.2 Functions ........................................................................................................... 1-3
2.3 Maintenance ...................................................................................................... 1-3
2.4 Machine Specifications ...................................................................................... 1-4
2.5 Operating Environment...................................................................................... 1-4
2.6 Controller ........................................................................................................... 1-4
II Composition/Operation
3. Center cross section ............................................................................................ 1-5
4. Paper path............................................................................................................ 1-6
5. Image creation process ........................................................................................ 1-7
1. Overall composition.............................................................................................. 2-1
1.1 Operation sequence .......................................................................................... 2-1
1.2 Control block diagram ........................................................................................ 2-2
2. Cartridge section.................................................................................................. 2-3
2.1 Composition....................................................................................................... 2-3
2.2 Drive .................................................................................................................. 2-4
2.3 Operation ........................................................................................................... 2-4
2.3.1 Drum Cartridge (DC) life control ................................................................... 2-4
2.3.2 Toner Cartridge (TC) life control ................................................................... 2-5
3. Photo Conductor section ...................................................................................... 2-6
3.1 Composition....................................................................................................... 2-6
3.2 Drive .................................................................................................................. 2-6
3.3 Operation ........................................................................................................... 2-7
3.3.1 Photo Conductor drive mechanism .............................................................. 2-7
3.3.2 Photo Conductor cleaning mechanism......................................................... 2-7
4. Charge Corona section ........................................................................................ 2-8
4.1 Composition....................................................................................................... 2-8
4.2 Operation ........................................................................................................... 2-9
4.2.1 Charge Corona Unit ON/OFF control ........................................................... 2-9
5. Write section (PH section).................................................................................. 2-10
5.1 Composition..................................................................................................... 2-10
5.2 Operation ......................................................................................................... 2-11
5.2.1 Outline ........................................................................................................ 2-11
i
5.2.2 Laser exposure process ............................................................................. 2-11

5.2.3 Laser emission timing................................................................................. 2-12
5.2.4 Laser emission area ................................................................................... 2-12
6. Developing section............................................................................................. 2-13
6.1 Composition .................................................................................................... 2-13
6.2 Drive ................................................................................................................ 2-15
I Outline
6.2.1 Developing drive control ............................................................................. 2-16

6.2.2 Toner flow ................................................................................................... 2-17
6.2.3 Developing bias .......................................................................................... 2-18
6.2.4 Developing system ..................................................................................... 2-18
6.2.5 Toner Cartridge Rack ................................................................................. 2-19
7. Image Transfer Section ...................................................................................... 2-24

7.1 Composition .................................................................................................... 2-24
7.1.1 1st transfer section ..................................................................................... 2-24
7.1.2 2nd transfer section .................................................................................... 2-26
7.2 Drive ................................................................................................................ 2-27
7.3 Operation......................................................................................................... 2-28
7.3.1 Transfer Belt cleaning mechanism.............................................................. 2-28
7.3.2 1st Transfer Roller voltage ON/OFF control ............................................... 2-31
7.3.3 2nd Transfer Roller pressure/retraction mechanism................................... 2-31
7.3.4 2nd Transfer Roller cleaning....................................................................... 2-33
7.3.5 Neutralization and separation of paper ...................................................... 2-34
7.3.6 Belt Positioning Sensor .............................................................................. 2-35
7.3.7 ATVC (Auto Transfer Voltage Control) ........................................................ 2-36
8. Toner collecting section...................................................................................... 2-37
8.1 Composition .................................................................................................... 2-37
8.2 Drive ................................................................................................................ 2-38
8.3 Operation......................................................................................................... 2-39
8.3.1 Toner collecting mechanism ....................................................................... 2-39
8.3.2 Waste toner full detection system .............................................................. 2-40
9. Paper feed section ............................................................................................. 2-41
9.1 Composition .................................................................................................... 2-41
9.2 Drive ................................................................................................................ 2-42
9.3 Operation......................................................................................................... 2-42
9.3.1 Paper feed control ...................................................................................... 2-42
9.3.2 Paper feed speed control ........................................................................... 2-42
9.3.3 Paper feed mechanism............................................................................... 2-43
9.3.4 Double feed prevention mechanism ........................................................... 2-43
ii
9.3.5 Paper empty condition detection ................................................................ 2-44

9.3.6 Paper feed retry function ............................................................................ 2-44
10. Conveyance Section/Registration Roller ............................................................ 2-45
10.1 Composition..................................................................................................... 2-45
10.2 Drive ................................................................................................................ 2-46
10.3 Operation ......................................................................................................... 2-46
I Outline
10.3.1 Registration Roller control .......................................................................... 2-46
10.3.2 OHP film detection...................................................................................... 2-47
10.3.3 Size error detection control......................................................................... 2-47
11. Fusing section .................................................................................................... 2-48
11.1 Composition..................................................................................................... 2-48
11.2 Drive ................................................................................................................ 2-49
11.3 Operation ......................................................................................................... 2-49
11.3.1 Heating Roller drive control ........................................................................ 2-49
11.3.2 Fusing temperature control......................................................................... 2-51
11.3.3 Protection against abnormally high temperature ........................................ 2-55
11.3.4 PPM control ................................................................................................ 2-56
12. Paper exit section ............................................................................................... 2-58
12.1 Composition..................................................................................................... 2-58
12.2 Drive (magicolor 2400W) ................................................................................. 2-59
12.3 Drive (magicolor 2430 DL)............................................................................... 2-59
13. Image stabilization control.................................................................................. 2-60
13.1 Overview.......................................................................................................... 2-60
13.2 Operation ......................................................................................................... 2-61
13.2.1 Leak detection control ................................................................................ 2-61
13.2.2 AIDC Sensor LED intensity control............................................................. 2-61
13.2.3 Reflectance measurement control.............................................................. 2-61
13.2.4 Control of the maximum amount of toner sticking ...................................... 2-61
13.2.5 Laser intensity adjustment control .............................................................. 2-61
13.2.6 γ correction control...................................................................................... 2-61
13.3 Operation timing .............................................................................................. 2-62
13.4 Operation flow.................................................................................................. 2-62
14. Other control ...................................................................................................... 2-63
14.1 Fan control ....................................................................................................... 2-63
14.1.1 Construction ............................................................................................... 2-63
14.1.2 Control ........................................................................................................ 2-64
14.2 Temperature/ Humidity Sensor ........................................................................ 2-65
14.2.1 Composition................................................................................................ 2-65
iii
I Outline
II Composition/Operation magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
iv
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 System configuration
I General
1. System configuration
1 A. magicolor 2400W
I Outline
[1]
[2]
4139fs1501c0
[1] Main Unit [2] Dust Cover
1 B. magicolor 2430 DL
[5] [1]
[4]
[2]
[3]
4139fs1502c0
[1] Duplex Option [4] 512 MB DIMM

[2] Dust Cover [5] Main Unit
[3] Lower Feeder Unit
1-1
Product specifications magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
2. Product specifications
2.1 Type
Type Desktop full-color laser beam printer
Printing System Semiconductor laser and electrostatic image transfer to plain paper
Exposure System 2 laser diodes and polygon mirror
I Outline
PC Drum Type OPC (organic photo conductor)

Photoconductor
Blade cleaning system
Cleaning
Print Density 2400 x 600 dpi, 1200 x 600 dpi, 600 x 600 dpi
magicolor 2400W One-way system (Tray 1: 200 sheets)
1 Paper Feeding System One-way system (Tray 1: 200 sheets)

magicolor 2430 DL * Expandable to a two-way system by adding an
optional Lower Feeder Unit.
Developing System Single-element developing system
Charging System DC comb electrode Scorotron system
Image Transfer
Intermediate transfer belt system
System
Paper Separating
Curvature separation + Charge-neutralizing system
System
Fusing System Roller fusing
Paper Exit System Face down (Output Tray capacity: 200 sheets)
1-2
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Product specifications
2.2 Functions
Average: 45 seconds
110 V to 127 V area (at ambient temperature of 23°C/73.4°F and rated
source voltage)
Warm-up Time
Average: 49 seconds
220 V to 240 V area (at ambient temperature of 23°C/73.4°F and rated
source voltage)
I Outline
Plain paper 126.78 mm/second
System Speed Thick stock 63.39 mm/second
OHP film 42.26 mm/second
Full Color 1-sided: 21 seconds
magicolor 2400W
Monochrome 1-sided: 12 seconds
First Page Out Time 1-sided: 21 seconds
1 Full Color
(Plain Paper) 2-sided: 33 seconds
magicolor 2430 DL
1-sided: 12 seconds
Monochrome
2-sided: 24 seconds
Full Color 1-sided: 5 pages/minute
magicolor 2400W
Monochrome 1-sided: 20 pages/minute
Print Speed 1-sided: 5 pages/minute
1 (Plain Paper) Full Color
2-sided: 5 pages/minute
magicolor 2430 DL
1-sided: 20 pages/minute
Monochrome
2-sided: 11.4 pages/minute
Paper width: 92 to 216 mm (3.6" to 8.5")
Paper Size
Paper length: 148 to 356 mm (5.9" to 14")
• Plain Paper (60 to 90 g/m2 / 16 to 24 lb)
• Recycled Paper (60 to 90 g/m2 / 16 to 24 lb)
• Transparencies
• Thick stock (91 to 163 g/m2/ 25 to 40 lb)
Paper Type • Postcards
• Envelopes
• Letterhead
• Label stock
• Glossy stock
Plain paper, recycled paper, and letterhead :200 sheets
Transparencies, thick stock, postcards, labels stock,
Tray Capacity
and glossy stock :50 sheets
Envelopes :10 sheets
2
1 Lower Feeder Unit: Only plain paper and recycled paper weighing 60 to 90 g/m
(16 to 24 lb) can be loaded.
Duplex Option: Only plain paper and recycled paper weighing 60 to 90 g/m2
(16 to 24 lb) can be fed through the unit.
☞ For details, see the Field Service Manual for each option.
2.3 Maintenance
Machine Durability 200,000 prints or 5 years, whichever comes first
1-3
Product specifications magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
2.4 Machine Specifications
Power Requirements AC 110 to 127 V

Voltage: AC 220 to 240 V
Frequency: 50/60 Hz ± 3 Hz
Max Power
1100 W
Consumption
I Outline
430 (W) x 395 (D) x 341 (H) mm

Dimensions
16.9" (W) x 15.6" (D) x 13.4" (H)
Weight Approx. 19.9 kg (43.9 lb) (excluding the Dust Cover)
During standby : 35 dB (A) or less
Operating Noise
During printing : 53 dB (A) or less
2.5 Operating Environment
Temperature 10 to 35° C / 50 to 95° F (with a fluctuation of 10° C / 18° F or less per hour)
Humidity 15 % to 85 % (with a fluctuation of 20 %/h)
2.6 Controller
1 A. magicolor 2400W
CPU N4-Chip
Standard Memory 32 MB
Interface USB 1.1/2.0 (High Speed) compliant
Printer Driver GDI Printer Driver
OS Compatibility Windows 98SE/Me/2000/XP
1 B. magicolor 2430 DL
CPU TAK pro800 130 MHz

Standard Memory 32 MB
Interface USB 1.1/2.0, 10Base-T/100Base-TX (IEEE 802.3) Ethernet
Windows Windows GDI based drive/PageScope Raster Language
Mac OS 9 Raster based driver/PageScope Raster Language
Printer Driver CUPS 1.15 or later/GhostScript (for Mac OS X10.2 only)/

Mac OS X
PageScope Raster Language
CUPS 1.15 or later/GhostScript/
Linux
PageScope Raster Language
OS Compatibility Windows 98SE/NT4.0/Me/2000/Server 2003/XP, Mac OS 9.04/X10.2, Linux
NOTE
• These specifications are subject to change without notice.
1-4
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Center cross section
3. Center cross section
[6] [7]
I Outline
[5]
[4]
[3]
[2]
[1]
4139to1590c0
[1] Paper Feed Section [4] Drum Cartridge Section

[2] Write Section [5] Transfer Belt Section
[3] Toner Cartridge Section [6] 2nd Transfer Section
[7] Fusing section
1-5
Paper path magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
4. Paper path
A. magicolor 2400W
I Outline
4139to1591c0
B. magicolor 2430 DL
4139to1502c0
1-6
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Image creation process
5. Image creation process
[8] Paper Separation

[7] 2nd Image Transfer
I Outline
[9] Transfer Belt Cleaning
[6] 1st Image Transfer
[3] Photo [10] PC Drum Cleaning

conductor
[5] Developing
[4] Photo Conductor Charging
[1] Printer Image Processing [2] Laser Exposure
Printer Image • The intensity of the laser light is controlled by the image signal sent
[1]
Processing from the host computer.
• The image projected onto the surface of the Photo Conductor is con-
[2] Photo conductor
verted to a corresponding electrostatic latent image.
Photo Conductor • A negative DC charge layer is formed on the surface of the Photo
[3]
Charging Conductor.
• The surface of the Photo Conductor is irradiated with the laser light
[4] Laser Exposure
and an electrostatic latent image is thereby formed.
• The toner, negatively charged in the Hopper, is attracted onto the
electrostatic latent image formed on the surface of the Photo Conduc-
tor. It is thereby changed to a visible, developed image.
[5] Developing
• A DC negative bias voltage is applied to the Developing Roller,
thereby preventing toner from sticking to the background image por-
tion.
• A DC positive voltage is applied to the backside of the Transfer Belt,
[6] 1st Image Transfer thereby allowing the visible, developed image on the surface of the
Photo Conductor to be transferred onto the Transfer Belt.
• A DC positive voltage is applied to the backside of the paper, thereby
[7] 2nd Image Transfer allowing the visible, developed image on the surface of the Transfer
Belt to be transferred onto the paper.
• The paper, which has undergone the 2nd image transfer process, is
[8] Paper Separation
neutralized.
• A charge is applied to the Transfer Belt. By potential difference, resid-
[9] Transfer Belt Cleaning
ual toner on the surface of the Transfer Belt is collected for cleaning.
Photo Conductor • The residual toner left on the surface of the Photo Conductor is
[10]
Cleaning scraped off.
1-7
I Outline Image creation process magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
Blank Page
1-8
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Overall composition
1. Overall composition
1.1 Operation sequence
Print Request
Fusing Motor (M7)
Main Motor (M1)
Polygon Motor
Charge output
1st transfer output
2nd transfer output
2nd Transfer Roller retracted
Pressure/Retraction Solenoid
/Cleaning Blade (SL3)
Developing Motor (M3)
Rack Motor (M2)
Tray1 Paper Pick-up Solenoid (SL1)
Registration Roller Solenoid (SL2)
Registration Sensor (PC1)
Exit Sensor (PC7)
C-TOD
4139to2049e0
2-1
Overall composition magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
1.2 Control block diagram
TC/Y TC/M TC/C TC/K

Control Panel (PWB-OP)
Paper Pick-up/ Mechanical Control Print Control Board (PWB-P)

transport Board (PWB-A)
CPU Image processing

Image process
Fusing
Power supply/
high voltage Write Unit (PH)
Duplex Unit* Lower Feeder Unit*
*magicolor 2430DL Only
Control System Line
Image Bus Line

4139to1596e0
2-2
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Cartridge section
2. Cartridge section
2.1 Composition
Drum Cartridge
4139to1569c1 4139to2053e0
Toner Cartridge
4139to2054e0
2-3
Cartridge section magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
2.2 Drive
Main Motor
Drum Cartridge
Photo Conductor
Developing Motor
Toner Cartridge
4139to2055e0
2.3 Operation
2.3.1 Drum Cartridge (DC) life control
• The Drum Cartridge offers the following life controls: detecting a new DC and resetting
the life counter.
A. New DC detection
• The machine attempts to perform a new DC detection sequence when the Power Switch
is turned OFF and ON, or the Front Door is closed.
• If no new DC is detected, the image stabilization sequence is not carried out.
• If a new DC is detected, the image stabilization sequence is carried out.
B. Reaching the life

• The life counter is reset when a new DC is detected.
• The machine gives a warning message when the life value is reached (printing will be
continued). When the Waste Toner reaches its full level, the initiation of any new print
cycle will be prohibited. The machine then prompts the user to replace the DC.
2-4
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Cartridge section
2.3.2 Toner Cartridge (TC) life control

A. Toner Cartridge detection and new cartridge detection timing
• The machine attempts to perform a detection sequence when the Front Door is closed.
B. Toner Cartridge detection
• The machine accesses the TC Detection Board (CSIC) to check for data stored in it.
Using that data, the machine determines whether or not a Toner Cartridge is loaded.
C. New Toner Cartridge detection
After a Toner Cartridge has been detected, the machine determines whether it is new or not
based on the data acquired.
D. Toner Cartridge near empty and empty condition detection
• The amount of toner consumed is calculated from the number of dots produced for one
printed page by the controller. A toner near empty condition and a toner empty condition
are thereby detected.
<Toner near empty decision>
1. The machine determines that there is a toner near empty condition when the image
counter and dot counter reach the life value.
<Toner empty decision>

2. The machine determines that there is a toner empty condition when a predetermined
number of printed pages are produced after the toner near empty condition has been
detected.
2-5
Photo Conductor section magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
3. Photo Conductor section

3.1 Composition
Drum Cartridge
Photo Conductor
4139to1570c1 4139to2056e0
Charge Generating Layer
Charge Transport Layer Aluminum Base
4139to2057e0
3.2 Drive
Main Motor
Photo Conductor
4139to1058e0
2-6
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Photo Conductor section
3.3 Operation
3.3.1 Photo Conductor drive mechanism
• The Photo Conductor is driven by the Main Motor (M1).
• When the Main Motor (M1) is energized, it turns the drive gear, which in turn rotates the
Photo Conductor.
3.3.2 Photo Conductor cleaning mechanism
• The Cleaning Blade is pressed up against the surface of the Photo Conductor, scraping
residual toner off the surface.
• The toner scraped off the surface of the Photo Conductor is collected in the Drum Car-
tridge.
Cleaning Blade
4139to2059e0
2-7
Charge Corona section magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
4. Charge Corona section

4.1 Composition
[1]
4139to1570c1
4139to1523c0
[3]
[2]
4139to2010c1
Key Name Function/System

• Deposits a charge to the surface of the Photo Conductor.
[1] Charge Corona
• DC comb electrode Scorotron system
• DC comb electrode Scorotron system
[2] Electrode • Using the comb electrode ensures that the charge is concentrated
on the grid mesh, thus reducing the amount of ozone produced.
• Evens out the charge deposited from the Electrode to make the
surface potential uniform throughout the surface of the Photo
[3] Grid Mesh
Conductor.
• The grid voltage is applied to the Grid Mesh.
2-8
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Charge Corona section
4.2 Operation
4.2.1 Charge Corona Unit ON/OFF control
• The grid voltage (Vg) applied to the Grid Mesh is controlled by image stabilization con-
trol.
Standby Position
Polygon Motor Energized
Belt Positioning
K Toner Developing Position Sensor Activated
Y M C K Y
Rack Motor (M2)
Main Motor (M1)
Charge output bias
4139to2060e0
2-9
Write section (PH section) magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
5. Write section (PH section)

5.1 Composition
4139to1568c0 4139to2002c0
[3]
[2]
[4]
[1]
[5]
[8] [7]
[6]
4139to2001c1

[1] SOS Mirror • Condenses the incident laser light onto the SOS Sensor.
• Condenses the incident laser light, with which the Photo Conduc-
[2] G2 Lens
tor is irradiated.
• Emits a laser light.
[3] Semiconductor Laser
• Two-beam array LD
[4] SOS Sensor • Produces an SOS signal using the incident laser light.
[5] G1 Lens • Corrects the condensing angle of the incident laser light.
• Scans the incident laser light in the main scan direction and
[6] Polygon Mirror reflects it onto the G1 Lens.
• Four-face polygon mirror
• Reflects the laser light condensed by the G1 Lens onto the G2
[7] Return Mirror
Lens.
[8] G2 Lens (SOS Lens) • Condenses the incident laser light onto the SOS Sensor.
2-10
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Write section (PH section)
5.2 Operation
5.2.1 Outline
• The surface of the Photo Conductor is irradiated with a laser light and an electrostatic
latent image is thereby formed.
• The Polygon Mirror has four faces. The machine uses a two-beam array LD to inhibit the
speed of the Polygon Mirror from increasing because of the decreased number of faces
the Polygon Mirror has as compared with the conventional models.
• The two-beam array LD consists of two LD elements arranged vertically. Two lines are
scanned with two laser beams emitted from these two LD elements through a single face
of the Polygon Mirror.
scan motion.
Photo Conductor Surface
Two lines are

of Photo Conductor scanned in a single
Beam A
Beam B
Beam A
Beam B Photo
Conductor
Direction of Rotation
Direction of Rotation
of Photo Conductor
Laser Diode G2 Lens
G1 Lens
Polygon Mirror Return Mirror
4139to2051e0
5.2.2 Laser exposure process

1. The laser light emitted from the Semiconductor Laser strikes the Polygon Mirror.
2. The Polygon Mirror with four faces is rotated at high speeds by the Polygon Motor.
3. The SOS Sensor ensures that the laser light emission start timing remains constant for
each line of main scan.
Photo Conductor
Semiconductor Laser
SOS Board
Polygon Motor
4139to2052e0
2-11
Write section (PH section) magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
5.2.3 Laser emission timing

• When a Ready signal is detected after the lapse of a given period of time after the print
cycle has been started, a Laser ON signal is output from the Print Control Board (PWB-
P).
• The Laser ON signal triggers the firing of each laser light which illuminates the SOS
Board via the Polygon Mirror, G1 Lens, Return Mirror, G2 Lens (SOS Lens), and SOS
Mirror. This generates an SOS signal.
• This SOS (Start of Scan) signal unifies the timing at which the laser lights are irradiated
for each main scan line.
5.2.4 Laser emission area
A. Main scan direction (CD)
• The print start position in the CD direction is determined by the CD Print Start signal (/
HSYNC) that is output from the Print Control Board (PWB-P) and the width of the paper.
• The laser emission area is determined by the paper size. The area of 4 mm on both
edges of the paper is, however, the void image area.
B. Sub scan direction (FD)

• The print start position in the FD direction is determined by the Image Write Start signal
(/TOD) that is output from the Print Control Board (PWB-P) and the length of the paper.
• The laser emission area is determined by the paper size. The area of 4 mm on both the
leading and trailing edges of the paper is, however, the void image area.
Void width: 4 mm Void width: 4 mm
Void width: 4 mm
Void width: 4 mm
4138to2595c0
2-12
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Developing section
6. Developing section
6.1 Composition
4139to1569c1
[1]
[2]
4139to2013c1
[9]
[3] [10]
[11]
[4]
[5] [12]
[8]
[6]
[7]
4139to1524c1 4139to1520c0
2-13
Developing section magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004

• Drives the Photo Conductor.
[1] Main Motor (M1) • Driven by the Mechanical Control Board (PWB-A).
• Brushless DC motor.
• Drives the Developing Roller.
[2] Developing Motor (M3)
• Pulse motor.
• Loaded with toner that is conveyed onto the Developing Unit by
[3] Hopper
way of the Conveyance Pipe.
[4] Supply Roller • Supplies toner fed off from the Hopper to the Developing Roller.
• Supplies toner fed by the Supply Roller to the surface of the Photo
Conductor.
• Conveys toner to the surface of the Photo Conductor through
[5] Developing Roller
potential difference.
• The developing bias voltage is applied to this roller.
• Single component developing system.

[6] Regulator Blade/2nd • Regulates the height of toner on the surface of the Developing
Roller.
[7] Regulator Blade/1st • The blade bias voltage is applied to the blade.
[8] Agitating Blade • Agitates toner in the Hopper.
• The drum surface on which an image of each color of toner is
[9] Photo Conductor formed for subsequent transfer of the image to the Transfer Belt.
• OPC drum (φ 30 mm).
[10] Cleaning Blade • Scrapes residual toner off the surface of the Photo Conductor.
• Evens out waste toner scraped off by the Cleaning Blade and that
Waste Toner Agitating
[11] scraped off by the Cleaning Blade of the Image Transfer Belt so
Screw
that the waste toner can be stored evenly.
• Deposits a charge to the surface of the Photo Conductor.
[12] Charge Corona
• DC comb electrode Scorotron system.
2-14
6.2 Drive
[2]
[1]
[3]
[4]
4139to2014c1
[1] Photo Conductor [3] Developing Motor (M3)

[2] Main Motor (M1) [4] Developing Roller
2-15
A. Developing Roller drive

• The Developing Roller is driven by the Developing Motor (M3) and Intermediate Gear.
• When the Toner Cartridge Rack is stationery at the developing position, the Developing
Roller Drive Gear comes into mesh with the Intermediate Gear. The Developing Roller is
then rotated through the drive provided by the Developing Motor (M3) and Intermediate
Gear.
[1]
[2]
[3]
4139to1530c0
[1] Developing Roller Drive Gear [3] Developing Motor (M3)

[2] Intermediate Gear
6.2.1 Developing drive control
Polygon Motor Energized

K Toner Standby Position
Developing Belt Positioning
Position Print Start Sensor Activated
Y M C K Y
Rack Motor (M2)
Developing bias AC
Developing bias DC
Main Motor (M1)
Charge output bias
4139to2102e0
2-16
6.2.2 Toner flow

1. Toner stored in the Hopper is agitated by the Agitating Blade and conveyed into the
Toner Supply Portion by the Conveyance Blade fitted to the leading edge of the Agitat-
ing Blade.
2. The toner conveyed into the Toner Supply Portion is conveyed by the Supply Roller
onto the Developing Roller.
3. At this time, Regulator Blade/1st and /2nd regulate the height of toner on the surface of
the Developing Roller.
4. Toner then sticks to the electrostatic latent image formed on the surface of the Photo
Conductor. That part of toner left on the surface of the Developing Roller is returned to
the Toner Supply Portion.
Hopper
Supply Roller
Developing Roller
Agitating Blade
Regulator Blade/2nd
Regulator Blade/1st
4139to2061e0
2-17
6.2.3 Developing bias

• The developing bias voltage (Vb) is applied to the Developing Roller so that an adequate
amount of toner is attracted onto the surface of the Photo Conductor.
• To allow toner to fly to the Photo Conductor easily, DC (-) + AC developing bias voltage
(Vb) is applied to the Developing Roller during development. This AC component of the
developing bias voltage is applied only during development. At any time other than the
development, only the DC (-) component of the developing bias voltage is applied.
• The developing bias voltage (Vb) is supplied by the High Voltage Unit (HV).
Developing Bias Contact Point Seal Bias Contact Point

Regulator Blade Contact Points 4139to2062e0
6.2.4 Developing system

• The machine employs the single-component, non-contact developing system.
• In the non-contact, single-component developing system, the magnetic brush does not
rub the surface of the Photo Conductor (or the image). This prevents a foggy image from
occurring and the Photo Conductor from being worn.
Developing Roller
Photo Conductor
4139to2063e1
2-18
6.2.5 Toner Cartridge Rack

• The Toner Cartridge Rack is mounted with four Toner Cartridges. The rack employs a
rotary system.
• Development of the image of each color of toner is performed by rotating the Toner Car-
tridge Rack.
Y Toner K Toner
Cartridge Cartridge
C Toner
M Toner Cartridge
Cartridge
4139to2064e0 4139to1528c0
A. Toner Cartridge Rack drive

• The Toner Cartridge Rack is driven by the Rack Motor (M2).
Rack Motor
4139to2066e0
Rack Motor
4139to2065e0
2-19
B. Toner Cartridge Rack stop position

• The Toner Cartridge Rack must be brought to a stop so that the Toner Cartridge of each
color of toner is located at its correct position. To accomplish this task, three stop posi-
tions are established: the standby (reference) position, the developing position, and the
cartridge replacement position.
• The standby position refers to the position at which the Toner Cartridge Rack is station-
ary when the machine is in the standby state. The Toner Cartridge Rack is located at this
standby position when the machine completes a warm-up cycle or waits for a print com-
mand.
• The development position refers to the position at which the Toner Cartridge Rack stops
during development of a specific color of toner.
• The cartridge replacement position refers to the position at which the Toner Cartridge
Rack is stopped for replacement of the Toner Cartridge of a specific color of toner.
(1) Standby (reference) position

• The standby position is 45° before the developing position of the K Toner Cartridge.
C
K
M
Y 45˚
Standby Position
4139to2067e0
(2) Developing position

• The developing position is where the Toner Cartridge Rack is rotated 45° from the
standby position.
For Developing of K
Photo Conductor
C C K
K
M 0˚
M Y
Y 45˚
Developing Position
4139to2068e0
2-20
(3) Cartridge replacement position

• The cartridge replacement position is where the Toner Cartridge Rack is rotated 70° from
the developing position.
For Developing of K
70˚
K
C K
Y
C
M Y M
K Developing Position Cartridge Replacement Position
4139to2069e0
C. Monochrome printing process

(1) Operation sequence
1. The Toner Cartridge Rack is stationary at the standby position.
2. When a print request is received from the controller, the Toner Cartridge Rack is
rotated to bring the K Toner Cartridge to its developing position.
3. Development of monochrome printing is started.
4. When the development is completed, the Toner Cartridge Rack is rotated and brought
to a stop at the standby position.
Step 1 Step 2 Step 3 Step 4
C C K C K C
M K M K
Y M Y M Y Y
Standby Position Rack is Rotated Monochrome Printing Standby Position
4139to2070e0
2-21
D. Color printing process

(1) Operation sequence
1. The Toner Cartridge Rack is stationary at the standby position.
2. When a print request is received from the controller, the Toner Cartridge Rack is
rotated to bring the Y Toner Cartridge to its developing position.
3. Development of Y is carried out.
4. When development of Y is completed, the Toner Cartridge Rack is rotated to bring the
M Toner Cartridge to its developing position.
5. Development of M is carried out.
6. Similarly, the Toner Cartridge Rack is rotated and development of C is carried out.
7. Similarly, the Toner Cartridge Rack is rotated and development of K is carried out.
8. When the development of K is completed, the Toner Cartridge Rack is rotated and
brought to a stop at the standby position.

C K Y K Y Y M
M K
Y C M C M K C
Standby Position Rack is Rotated Y Development Rack is Rotated
Y M M C C K C
M K
K C Y K M Y Y
Rack is Rotated Rack is Rotated

M Development + + Standby Position
C Development K Development 4139to2071e0
E. Toner Cartridge Rack stop position detection

• The Toner Cartridge Rack stop position for each color of toner is detected by the Rack
Motor (M2) and the Rack Positioning Sensor (PC3).
• The Toner Cartridge Rack is provided with slits, each for a specific color of toner. When
the rack rotates, the Rack Positioning Sensor (PC3) is blocked and unblocked.
A specific stop position is detected when the Rack Positioning Sensor (PC3) is blocked
and unblocked.
Slits
Rack Positioning Sensor 4139to2072e0 4139to1583c0
2-22
(1) Toner Cartridge Rack standby position

• The standby position is 45 ° before the developing position of the K Toner Cartridge. The
Y Toner Cartridge is therefore provided with a slit for detecting the K developing position.
• When the Toner Cartridge Rack is rotated, the Rack Positioning Sensor (PC3) moves
past the slit for detecting the K developing position. This allows the machine to determine
that the current development is for K. Through pulse control of the Rack Motor, the
machine then successfully brings the Toner Cartridge Rack to its standby position.
Direction of Rotation of
the Toner Cartridge Rack
C
M K Toner Cartridge
Rack Standby
Rack Positioning Y Position
Sensor
Standby Position Detecting Position
K C M Y
Detection of C Detection of M Detection of Y Detection of K

Developing Developing Developing Developing
Position Position Position Position 4139to2073e0
(2) Toner Cartridge Rack developing position

• To bring the Toner Cartridge Rack to a stop at the corresponding developing position, the
rack is rotated from the standby position 45° through pulse control of the Rack Motor.
(3) Cartridge replacement position
• When a request is made for replacing the Toner Cartridge of a specific color of toner (by
means of an input from the control panel, upon a toner empty condition, or through an
input made via the printer driver), the Toner Cartridge Rack is rotated 70° from the devel-
oping position through pulse control of the Rack Motor.
2-23
Image Transfer Section magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
7. Image Transfer Section

7.1 Composition
7.1.1 1st transfer section
4139to1571c1 4139to2019c0
[1]
[2]
[3]
[9]
[4]
[8]
[7]
[6] [5]
4139to1514c0
Key Name Function/system

[1] Driven Roller • Rotated as driven by the Transfer Belt.
• The image of each color of toner is transferred from the 1st Transfer
[2] Transfer Belt Roller to this Transfer Belt in the order of Y, M, C, and K, thereby forming
a full color toner image.
• Transfers the toner image from the Photo Conductor to the Transfer Belt
(1st transfer).
[3] 1st Transfer Roller • The 1st transfer voltage (T1) is applied.
• No mechanism is provided for retracting and pressing the 1st Transfer
Roller.
Transfer Belt Drive • Drives the Transfer Belt.
[4] • Driven by the Main Motor (M1).
Roller
• Detects the position of the Transfer Belt as the sensor is blocked/
Belt Positioning
[5] unblocked by a hole for detecting the Transfer Belt position provided in
Sensor (PC4)
the Transfer Belt.
2-24
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Image Transfer Section

• The drum surface on which an image of each color of toner is formed for
[6] Photo Conductor
subsequent transfer of the image to the Transfer Belt.
Toner Collecting • Conveys toner scraped off by the Cleaning Blade onto the Drum Car-
[7]
Screw tridge.
[8] Cleaning Blade • Scrapes residual toner off the surface of the Transfer Belt.
AIDC Sensor
[9] • Detects the toner density on the Image Transfer Belt.
(AIDC)
2-25
7.1.2 2nd transfer section
4139to1572c1 4139to2020c0
[1]
[4]
[2]
[3] 4139to1548c0
[2]
[1]
4139to2021c1

[1] 2nd Transfer Roller • Driven to rotate by the Transfer Belt.
Pressure/Retraction • Moved via a gear coupled to it when the Pressure/Retraction
[2]
Slider Solenoid/2nd Image Transfer (SL4) is energized.
Pressure/Retraction • When the Pressure/Retraction Slider moves, it comes into con-
[3]
Roller tact with this roller, which presses the 2nd Transfer Roller.
• Transmits the driving force of the Main Motor (M1) to the pressure
Pressure/Retraction
[4] cam.
Clutch
• Mechanical clutch
2-26
7.2 Drive
[1]
[5]
[4]
[2]
[3] 4139to2022c0
[1] Main Motor (M1) [4] Transfer Belt Drive Roller

[2] Image Transfer Belt Unit [5] 2nd Transfer Roller
[3] 1st Transfer Roller
2-27
7.3 Operation
7.3.1 Transfer Belt cleaning mechanism
• To scrape residual toner off the surface of the Transfer Belt, there is a Cleaning Blade
provided.
• The Cleaning Blade is pressed up against the Transfer Belt, thereby scraping residual
toner off the surface of the Transfer Belt.
• The Toner Collecting Screw conveys toner scraped off by the Cleaning Blade onto the
Drum Cartridge.
Driven Roller
Cleaning Blade
Toner Collecting Screw
4139to2074e0
2-28
A. Cleaning Blade pressure/retraction mechanism

• In color printing, an image is formed on the Transfer Belt for each color of toner. The
Cleaning Blade is therefore provided with a pressure/retraction mechanism.
• In monochrome printing, no retraction sequence is carried out.
• The Cleaning Blade is normally in pressed contact with the Transfer Belt.
(1) Pressure/retraction operation

• The Cleaning Blade pressure/retraction operations are performed by the Main Motor
(M1), Pressure/Retraction Solenoid /Cleaning Blade (SL3), pressure cam, lever, and
Retraction Position Sensor /Cleaning Blade (PC6).
• When the Pressure/Retraction Solenoid /Cleaning Blade (SL3) is energized, drive from
the Main Motor (M1) is transmitted to the pressure cam.
Pressure/Retraction Solenoid /Cleaning Blade
Lever
Pressure Cam
Main Motor
Retraction
Position Sensor
/Cleaning Blade
Belt Cleaner Assy

4139to2075e0
2-29
(2) Operation timing
SL3 Energization Signal (after Main Motor has been energized)

When power is turned ON:
Main Motor (M1)
Pressure/Retraction Solenoid To pressed position

/Cleaning Blade (SL3)
Retraction Position Sensor
/Cleaning Blade (PC6)
Y-TOD (CD Print Start signal for yellow) K print completed

During print cycle:
Main Motor (M1)
Pressure/Retraction Solenoid To retracted position

/Cleaning Blade (SL3) To pressed position
Retraction Position Sensor
/Cleaning Blade (PC6)
4139to2076e0
(3) Retraction sequence

1. Drive from the Main Motor (M1) is transmitted to the drive gear.
2. Rotation of the drive gear is transmitted to the pressure cam.
3. When the Pressure/Retraction Solenoid /Cleaning Blade (SL3) is energized, the half-
moon-shaped pressure cam rotates a half turn to push the lever forward.
4. When the lever is pushed forward, the Cleaning Blade is retracted.
5. When the Cleaning Blade is retracted, it results in the Cleaning Blade being retracted
from the Transfer Belt.
6. During this time, the Retraction Position Sensor /Cleaning Blade (PC6) detects whether
or not the Cleaning Blade is retracted from the Transfer Belt.
Lever
Pressure Cam
4139to2077e0
2-30
(4) Pressure sequence

1. When the Pressure/Retraction Solenoid /Cleaning Blade (SL3) is energized in the con-
dition, in which the Cleaning Blade is retracted from the Transfer Belt, the pressure cam
rotates a half turn. This pushes the lever backward.
2. When the lever is pushed backward, the Cleaning Blade is returned. Then, the Clean-
ing Blade is pressed against the Transfer Belt.
Pressure Cam
Lever
4139to2078e0
(5) Home position detection

• The position of the Cleaning Blade is unknown when the Power Switch is turned ON or
the cover is opened and closed, the machine performs a home position detection
sequence during a warm-up cycle.
• During the warm-up cycle, the Pressure/Retraction Solenoid /Cleaning Blade (SL3) is
energized to start a pressure/retraction sequence. When the Retraction Position Sensor /
Cleaning Blade (PC6) is then blocked, the Pressure/Retraction Solenoid /Cleaning Blade
(SL3) is deenergized.
7.3.2 1st Transfer Roller voltage ON/OFF control
Image write start position for

Image write start position for
a paper size of A4 or smaller
a paper size greater than A4
Belt Positioning Sensor (PC4)
/TOD (Image Write Start signal)
Rack Motor (M2)
1st Transfer output
4139to2103e0
7.3.3 2nd Transfer Roller pressure/retraction mechanism

• In color printing, the toner image of each color of toner is transferred to the Transfer Belt
(thus a total of four times to cover the four colors of toner). Pressure/retraction control
with respect to the Transfer Belt is therefore provided for the 2nd Transfer Roller.
• In the standby state, the 2nd Transfer Roller is in a position retracted from the Transfer
Belt.
2-31
A. Pressure/retraction operation
• The pressure/retraction operation is performed by the Main Motor (M1), Pressure/
Retraction Solenoid /2nd Image Transfer (SL4), and Pressure/Retraction Clutch.
• When the Pressure/Retraction Solenoid /2nd Image Transfer (SL4) is energized, drive
from the Main Motor (M1) is transmitted to the Pressure/Retraction Clutch.
Main Motor Transfer Belt

2nd Transfer Assy
Pressure/Retraction Clutch
Pressure/Retraction Solenoid /
2nd Image Transfer
2nd Transfer Roller
Pressure/Retraction Clutch
4139to2079e0
(1) Pressure sequence

1. Drive from the Main Motor (M1) is transmitted to the drive gear.
2. Rotation of the drive gear is transmitted to the Pressure/Retraction Clutch.
3. When the Pressure/Retraction Solenoid /2nd Image Transfer (SL4) is energized, the
Pressure/Retraction Clutch rotates a half turn. This moves the Pressure Slider.
4. When the Pressure Slider is moved, ribs on the Pressure Slider push up the 2nd Trans-
fer Assy.
5. When the 2nd Transfer Assy is pushed up, the 2nd Transfer Roller is pressed up
against the Transfer Belt.
Pressure/Retraction Roller
2nd Transfer Assy Pressure/Retraction Solenoid/
2nd Image Transfer
Pressure Slider
Pressure/Retraction
Clutch
Ribs
2nd Image Transfer
4139to2080e0
2-32
(2) Retraction sequence

1. When the Pressure/Retraction Solenoid /2nd Image Transfer (SL4) is energized in the
condition in which the 2nd Transfer Roller is pressed against the Transfer Belt, the
Pressure/Retraction Clutch rotates a half turn. This moves the Pressure Slider.
2. When the Pressure Slider is moved, the 2nd Transfer Assy, which has been pushed up
by the ribs on the Pressure Slider, lowers.
3. When the 2nd Transfer Assy lowers, it allows the 2nd Transfer Roller to be retracted
from the Transfer Belt.
2nd Transfer Assy Pressure/Retraction Solenoid/

Pressure/Retraction Roller 2nd Image Transfer
Pressure Slider
Pressure/Retraction
Clutch
Ribs
2nd Transfer Roller
4139to2081e0
7.3.4 2nd Transfer Roller cleaning

• DC positive and negative transfer bias voltages are alternately applied to the 2nd Trans-
fer Roller. This allows toner residue on the surface of the 2nd Transfer Roller to be trans-
ferred back to the Transfer Belt, thus cleaning the 2nd Transfer Roller.
• The toner transferred back to the Transfer Belt is collected by the Cleaning Blade.
2nd Transfer Roller
Transfer Belt
4139to2082e0
2-33
A. Operation timing
The 2nd Transfer Roller cleaning sequence is carried out under any of the following timings.
• Power Switch is turned ON
• Cover is opened and closed
• A media error occurs during a print cycle.
• A paper empty condition occurs during a print cycle.
• A paper size error occurs during a print cycle.
After Transfer Belt cleaning
Pressure/Retraction Solenoid / Pressed Retracted

2nd Image Transfer (SL4)
2nd transfer cleaning bias
4139to2083e0
7.3.5 Neutralization and separation of paper

• To neutralize the paper that has undergone the 2nd transfer process, a Charge Neutraliz-
ing Cloth is provided for the guide plate after the 2nd Transfer Roller.
Charge Neutralizing Cloth

Charge Neutralizing Cloth
2nd Transfer Roller

Transfer Belt
4139to2084e0
2-34
7.3.6 Belt Positioning Sensor

• When development takes place in this machine, the image of each color of toner is
formed on the surface of the Transfer Belt. The leading edge of the image of each color
of toner must therefore be aligned correctly with each other on the surface of the Transfer
Belt.
• The position of the Transfer Belt is detected when the Belt Positioning Sensor (PC4)
detects detection holes provided in the Transfer Belt.
• There are two detection holes provided in the Transfer Belt. The image write start posi-
tion is varied according to the paper size. For a paper size of A4 or smaller, the image
write start position is aligned with detection hole A. For a paper size greater than A4,
detection hole B serves as the reference for the image write start position.
Direction of Rotation of Transfer Belt
Detection
Hole A
Detection
Hole B
Belt Positioning Sensor 4139to2104e0
2-35
7.3.7 ATVC (Auto Transfer Voltage Control)

• The ATVC, or Auto Transfer Voltage Control, is for optimizing the transfer output. A con-
stant current is made to flow through each of the Transfer Rollers. From the voltage
thereby detected, the resistance of each of the 1st Transfer Roller, 2nd Transfer Roller,
and Transfer Belt is measured. The ATVC then automatically adjusts the appropriate
image transfer output voltage to be applied to the 1st Transfer Roller and the 2nd Trans-
fer Roller during the print cycle.
A. Overview of ATVC operation
HV
Apply the constant current the 1st Constant
Transfer Roller voltage
Constant Measure Constant

current resistance current
Measure the resistance of the 1st

Transfer Roller.
2nd Transfer Roller 1st Transfer Roller
Establish the 1st transfer output

voltage. Transfer Belt Transfer Belt
Transfer Belt drive roller Photo Conductor

Apply the constant current the 2nd ground
Transfer Roller.
Measure the resistance of the 2nd

Transfer Roller.
Establish the 2nd transfer output

voltage.
B. 1st transfer ATVC operation

1. The data on the 1st transfer constant current for each color of toner output from the
High Voltage Unit (HV) is fed back to the High Voltage Unit via the 1st Transfer Roller,
Transfer Belt, and the Photo Conductor ground. The resistance of the Transfer Belt is
thereby measured.
2. Based on the measured resistance value, the optimum 1st transfer voltage is estab-
lished.
C. 2nd transfer ATVC operation

1. The data on the 2nd transfer constant current output from the High Voltage Unit (HV) is
fed back to the High Voltage Unit via the 2nd Transfer Roller, Transfer Belt, and the
Transfer Belt drive roller. The resistance of the Transfer Belt is thereby measured.
2. Based on the measured resistance value and inconsideration of the environmental con-
ditions and print color, the optimum 2nd transfer voltage is established.
2-36
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Toner collecting section
8. Toner collecting section

8.1 Composition
[1]
[2]
4139to1573c0
[3]
4139to1536c0

• Conveys waste toner scraped off by the Cleaning
[1] Toner Collecting Screw
Blade to the Waste Toner Conveyance Unit.
• Conveys the waste toner fed by the Toner Collecting
[2] Waste Toner Conveyance Unit
Screw into the Drum Cartridge.
• Evens out waste toner scraped off by the Cleaning
Blade and that scraped off by the Cleaning Blade of
[3] Toner Agitating Screw
the Image Transfer Belt so that the waste toner can
be stored evenly.
2-37
Toner collecting section magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
8.2 Drive
[1] [2]
[6]
[3]
[5]
[4]
4139to2028c0
[1] Toner Collecting Screw [4] Toner Agitating Screw

[2] Transfer belt [5] Main Motor (M1)
[3] Driven Roller [6] Waste Toner Conveyance Unit
2-38
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Toner collecting section
8.3 Operation
8.3.1 Toner collecting mechanism
• Waste toner scraped off by the Cleaning Blade of the Transfer Belt and that scraped off
by the Cleaning Blade of the Photo Conductor are conveyed by each of the Toner Col-
lecting Screws into the Drum Cartridge.
A. Image Transfer Belt Unit
• Waste toner scraped off by the Cleaning Blade is collected by the Toner Collecting Screw
for Transfer Belt.
• The waste toner collected by the Toner Collecting Screw is conveyed to the Drum Car-
tridge by way of the Waste Toner Conveyance Unit.
Toner Collecting Screw
Toner Agitating Screw
4139to2085e0
2-39
Toner collecting section magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
8.3.2 Waste toner full detection system

• A waste toner near full condition is detected using the output state of the Waste Toner
Near Full Detection Board (PWB-C).
• A waste toner near full condition is detected by letting the light emitted from the LED
mounted on the Waste Toner Near Full Detection Board (PWB-C) travel through the light
guide.
• To prevent false detection, the Drum Cartridge is provided with the Toner Agitating Screw
that ensures that the waste toner is evenly stored.
Waste Toner Detection Area
Light Guide
Waste Toner Near Full

Detection Board (PWB-C)
4139to2086e0
Light Guide LED Light Waste Toner

LED
Normal Condition At Waste Toner Near Full Condition

4139to2087e0
A. Waste toner near full condition detection control

• Light emitted from the LED mounted on the Waste Toner Near Full Detection Board
(PWB-C) is made to travel through the light guide. This light is blocked if the waste toner
reaches an upper limit, which allows the machine to determine that there is a waste toner
near full condition.
• To prevent false detection, the Drum Cartridge is provided with the Toner Agitating Screw
that ensures that the waste toner is evenly stored.
B. Waste toner full detection control
• The machine determines that there is a waste toner full condition when 200 images* are
reached after a waste toner near full condition has been detected. (*: The initiation of any
new print cycle is prohibited when 50 full-color printed pages are produced after the
waste toner near full condition has been detected.)
• When light of the LED on the Waste Toner Near Full Detection Board (PWB-C) is
unblocked after the Drum Cartridge has been replaced, the waste toner full condition is
reset.
2-40
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Paper feed section
9. Paper feed section

9.1 Composition
[1]
4139to1574c0 4139to2031c0
[4]
[3] [2]
4139to1537c0

• Tray1 paper tray, in which a paper stack is loaded
• Max. paper capacity
Plain paper: 200 sheets
[1] Lower Feeder Unit
Thick stock, OHP film, postcards, glossy stock,
labels: 50 sheets
Envelopes: 10
• Detects the amount of paper still available for used
[2] Tray1 Paper Empty Sensor (PC9)
in Tray1.
[3] Tray1 Paper Pick-up Solenoid (SL1) • Controls drive from the Main Motor (M1).
[4] Pick-up Roller • Pick-up paper from Tray1.
2-41
Paper feed section magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
9.2 Drive
[1]
[4]
[2]
[3]
4139to2032c0
[1] Main Motor (M1) [2] Pick-up Roller

[3] Tray1 Paper Pick-up Solenoid (SL1) [4] Paper Pick-up Clutch
9.3 Operation
9.3.1 Paper feed control
Print Start Signal

* C-TOD * C-TOD
Main Motor (M1)
Exit Sensor (PC7)
* C-TOD (Top of Data): CD Print Start signal for cyan 4139to2088e0
9.3.2 Paper feed speed control

• The Conveyance Roller and Registration Roller are driven by the Main Motor (M1).
• The appropriate paper feed and conveyance speed are selected according to the type of
paper.
Media Type Main Motor (mm/sec)

Plain paper, letterhead 126.78
Thick stock, postcards, labels, glossy stock 63.39
OHP film, envelopes 42.26
2-42
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Paper feed section
9.3.3 Paper feed mechanism

• When the Tray1 Paper Pick-up Solenoid (SL1) is energized, drive from the Main Motor
(M1) is transmitted to the Pick-up Roller via the Paper Pick-up Clutch. The Pick-up Roller
is thereby rotated.
• At the same time, the Lift Cam is rotated, which raises the Paper Lift Plate. This allows
the paper to be taken up and fed in by the Pick-up Roller.
Lift Cam Paper Lift Plate

Paper Lift Plate
Cam
4139to2101e0
4139to2089e0
9.3.4 Double feed prevention mechanism

• The fixed Separation Pad system plus the Claw Stoppers are used for paper separation.
This ensures that only the first sheet of paper is taken up and fed in.
Pick-up Roller
Separation Pad
4139to2090e0
Claw Stoppers
2-43
Paper feed section magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
9.3.5 Paper empty condition detection

• The Tray1 Paper Empty Sensor (PC9) is located on the underside of Tray1, detecting the
paper loaded in the tray.
• When there is paper loaded in the tray, the actuator drops into the tray, unblocking the
sensor light.
• When paper runs out, the actuator is raised, blocking the sensor light.
Actuator
Tray1 Paper Empty Sensor
4139to2091e0
9.3.6 Paper feed retry function

• To reduce the number of paper misfeeds detected due to failure to take up and feed in
paper properly, another paper feed sequence is carried out if the Registration Sensor
(PC1) is not unblocked and blocked within a predetermined period of time.
2-44
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Conveyance Section/Reg-
10. Conveyance Section/Registration Roller

10.1 Composition
[1] [2]
[3]
4139to1575c0 4139to1542c0
[1]
[5]
[4]
[6]
[3]
4139to1563c0

• Conveys the paper conveyed from the Conveyance
[1] Registration roller
Roller to the transfer section.
[2] OHP Sensor (PC2A) • Detects whether or not there is OHP film.
[3] Conveyance roller • Conveys paper from Tray1 to the Registration Roller.
• Detects the leading edge of the paper conveyed
[4] Registration Sensor (PC1)
from the Pick-up Roller.
• Drives the Conveyance Roller.
[5] Main Motor (M1)
• Driven by the Mechanical Control Board (PWB-A).
• Controls drive of the Registration Roller and Con-
[6] Registration Roller Solenoid (SL2)
veyance Roller.
2-45
Conveyance Section/Registration Roller magicolor 2400W/2430 DL Theory of Operation Ver.
10.2 Drive
[2]
[1]
4139to2035c0
[1] Registration Sensor (PC1) [2] Actuator
10.3 Operation
10.3.1 Registration Roller control
• The Registration Sensor (PC1) detects whether or not the paper has reached the Con-
veyance Section.
• Conveyance of paper is restarted by synchronizing the paper conveyed with the image.
• Since the Conveyance Roller and Registration Roller are synchronized with each other,
no loop is formed in the paper at the Registration Roller.
Paper feed sequence started

Drive stopped
4139to2105e0
2-46
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Conveyance Section/Reg-
10.3.2 OHP film detection

• To ensure that the paper of the correct type is being used, the OHP Sensor (PC2A)
detects the type of the paper being conveyed.
• When the Registration Sensor (PC1) is activated, the OHP Sensor (PC2A) is also acti-
vated and the type of paper being conveyed is determined if it is OHP film or any type
other than OHP.
• If the OHP Sensor (PC2A) is not deactivated, the machine determines that the paper is a
type other than OHP film. If the OHP Sensor (PC2A) is activated, the machine deter-
mines that the paper is OHP film.
• If the paper type specified by the controller when a print request is made does not match
the results of OHP Sensor (PC2A) detection, the machine suspends the print cycle and
displays a corresponding message on the control panel.
OHP Sensor
Registration Roller
OHP Sensor
Reflection Mirror
4139to2092e0 4139to2093e0
10.3.3 Size error detection control

• To prevent incorrect printed pages, the size of the paper being conveyed is detected
using the Registration Sensor (PC1).
• The length of the paper is detected based on the value calculated using the period of
time that begins when the sensor is activated and ends when it is deactivated.
• If the paper size specified by the controller does not match the paper size detected by
the Registration Sensor (PC1), the machine displays a corresponding message on the
control panel.
• The paper that has caused the size error is subject to the print processes. Operations for
the subsequent sheets of paper can be specified from the controller.
2-47
Fusing section magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
11. Fusing section

11.1 Composition
4139to1576c0 4139to1546c0
[8]
[3]
[1]
[2]
[7]
4139to1565c0
[6]
[4]
[5]
4139to1547c0

[1] Thermistor (TH1) • Detects the temperature of the Heating Roller.
• Detects an abnormally high temperature of the Heat-
[2] Thermostat (TS1)
ing Roller.
• Detects the paper conveyed from the Fusing Pres-
[3] Exit Sensor (PC7)
sure Roller and Fusing Roller.
• Applies pressure to the toner so that it is fused into
[4] Pressure Roller
the paper.
• Applies heat and pressure to the toner so that it is
[5] Heating Roller
fused into the paper.
• Heats the Heating Roller.
[6] Heater Lamp (H1)
• Heater Lamp power: 760 W
[7] Cleaning Roller • Removes paper dust from the Heating Roller.
[8] Fusing Motor (M7) • Drives the Heating Roller.
2-48
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Fusing section
11.2 Drive
Fusing Motor
Heating Roller
4139to2094e0
11.3 Operation
11.3.1 Heating Roller drive control
A. Speed change control
• Drive for the Heating Roller is provided by the Fusing Motor (M7).
• To prevent fusing failure, the fusing speed is changed in three steps according to the
media type.
Media Type Fusing Speed (mm/sec)

Plain paper, letterhead 126.78
Thick stock, postcards, labels, glossy stock 63.39
OHP film, envelopes 42.26
B. Speed stabilization
• To prevent double transferred image or brush effect, the difference between the fusing
speed and paper transport speed during image transfer is corrected.
• The fusing speed is changed in two steps relative to the system speed, either at high
speed (which is +2% of the system speed) or low speed (which is -2.5% of the system
speed).
• The Fusing Motor (M7) is controlled to achieve this speed change in two steps.
2-49
C. Operation flow
1. The initial fusing speed is set to the low speed, thereby forming a loop in the paper
between the 2nd Transfer Roller and Fusing Rollers.
2. When the length of the loop formed in the paper becomes greater, the Fusing Paper
Loop Sensor (PC8) is activated (blocked).
3. While the Fusing Paper Loop Sensor (PC8) remains activated, the fusing speed is kept
at the high level.
4. When the Fusing Paper Loop Sensor (PC8) is deactivated, the fusing speed is immedi-
ately switched to the low level.
5. The sequence of these operations is repeated so that the fusing speed is changed
automatically according to the loop length. This effectively makes for the difference
between the fusing speed and paper conveyance speed during image transfer.
4139to1592c0 4139to1593c0
2-50
11.3.2 Fusing temperature control

• A thermistor is used to detect the surface temperature of the Heating Roller. The Heater
Lamp (H1) is then turned ON and OFF as necessary to achieve the set temperature.
Temperature control during monochrome printing (Plain paper)
Power Switch ON
Warm-up completed
Print start
[1] [2] [3] [4]
(˚ C)
[*a]
185
180 [*b]
174
169
167
100
60
Ave. 45 seconds. 4139to2095e0
[1] During warm-up [3] During a print cycle

Heat the Heating Roller temperature to Heating Roller temperature setting: 169° C
178° C in average 45 seconds. (100 V *b: If the Temperature/Humidity Sensor
– 120 V area) (HS1) detects a temperature of less than 20°
Heat the Heating Roller temperature to C, temperature control is performed with the
178° C in average 49 seconds. (220 V Heating Roller temperature setting changed
– 240 V area) to 174° C.
[2] In standby state [4] In standby state
Heating Roller temperature setting: Heating Roller temperature setting: 180° C
180° C
*a: If the Heating Roller temperature is
60° C or less when the warm-up cycle
is started, temperature control is per-
formed with the Heating Roller temper-
ature setting changed to 185° C.
(5 min.)
After the lapse of the 5 min. period, the
temperature stabilizes at 180° C.
2-51
Temperature control during color printing (Plain paper)
Power Switch ON
Warm-up completed
Print start
[1] [2] [3] [4]

(° C)
[*b]
189 [*a]
184 185
180
167
100
60
Ave. 45 seconds. 4139to2096e0
[1] During warm-up cycle [3] During a print cycle

178° C in average 45 seconds. (100 V (if the Heater Roller temperature at the start
– 120 V area) of the warm-up cycle is 60° C or less)
178° C in average 49 seconds. (220 V (if the Heater Roller temperature at the start
– 240 V area) of the warm-up cycle is more than 60° C)
*b: Temperature control is performed
according to the temperature measured
with the Temperature/Humidity Sensor. For
details, see “(2) Color printing (1-sided).”
☞ 2-54
[2] In standby state [4] In standby state
Heating Roller temperature setting: Heating Roller temperature setting: 180° C
180° C
*a: If the Heating Roller temperature is
60° C or less when the warm-up cycle
is started, temperature control is per-
formed with the Heating Roller temper-
ature setting changed to 185° C.
(5 min.)
After the lapse of the 5 min. period, the
temperature stabilizes at 180° C.
2-52
A. Warm-up
• Control is provided until the Heating Roller temperature reaches 178° C.
• This control is performed when the Power Switch is turned ON, a malfunction or paper
misfeed is reset, the Energy Saver mode is canceled, or the door is opened and closed.
B. In standby
• The fusing temperature in the standby state is prevented from being dropped.
• The control temperature in the standby state after the warm-up cycle which was started
with the Heating Roller temperature 60° C or less is changed to that of the ordinary
standby after the lapse of a predetermined period of time.
Standby State Temperature (° C)

Ordinary standby 180*a
In standby state after the warm-up cycle started with the Heating Roller tem-
185
perature below 60° C
*a: The fusing temperature in the standby state is changed if the standby state lasts for 20
min. or longer.
Machine interior temperature is less than 20° C: 170° C
Machine interior temperature is 20° C or more: 165° C
C. During print cycle

• To ensure good fusing performance, the set temperature of each roller is varied accord-
ing to the paper type and environment.
(1) Monochrome printing

• Temperature control is changed back to that listed under “Ordinary Environment” in the
table when the Temperature/Humidity Sensor (HS1) detects 20° C or more.
Ordinary Temperature/
Media Type environment humidity Sensor
(° C) less than 20° C (° C)
Plain paper (plain paper, letterhead) 169 174
Plain paper (plain paper, letterhead) 257 mm or less 169 174
Thick stock (thick stock, postcards, labels) 169
OHP 169
Envelopes 194*a
Glossy stock 169
*a: The temperature is controlled at 159° C if the machine interior temperature is 20° C or
more and humidity is 40% or higher.
2-53
(2) Color printing (1-sided)

• If the print cycle is started in a condition, in which the Temperature/Humidity Sensor
(HS1) detects 20° C or more, control is returned back to one having a control tempera-
ture of more than 60° C after five printed pages have been produced.
Heating Roller Temperature/ Temperature/

Ordinary
temperature at humidity humidity
Media Type environment
the start of Sensor less Sensor 28° C
(° C)
warm-up cycle than 20° C (° C) or more (° C)
60° C or less 189 194 189
Plain paper (plain paper, letterhead)
More than 60° C 184 189 184
Plain paper (plain paper, letterhead) 60° C or less 189 194 189
257 mm or less More than 60° C 184 189 184
Thick stock (thick stock, postcards,
- 184
labels)
OHP - 179
Envelopes - 194*a
Glossy stock - 190 190 185
*a: The temperature is controlled at 159° C if the machine interior temperature is 20° C or
more and humidity is 40% or higher.
D. Energy Saver mode

• Heater control is suspended when a malfunction or paper misfeed occurs or in the
Energy Saver mode.
(1) Control start timing
• The door is opened or a malfunction or paper misfeed occurs
• A request for Energy Saver mode is granted
(2) Control termination timing
• All of the following events are canceled: door open, an error or malfunction that has
occurred, and Energy Saver mode.
2-54
11.3.3 Protection against abnormally high temperature

• The machine provides protection at three different stages to prevent abnormally high
temperature of the Fusing Unit.
A. Soft protection
• If the Thermistor (TH1) detects a temperature exceeding a predetermined value, the mal-
function code representing abnormally high temperature is displayed. At this time, the
Heater Lamp (H1) is turned OFF forcibly and the initiation of any new print cycle is pro-
hibited (abnormally high temperature detection control).
B. Hard protection
• If the CPU overruns and the output level of the CPU of the Mechanical Control Board
becomes a HIGH or LOW level, and not a pulse output, and a predetermined tempera-
ture or higher is detected, a circuit within the Mechanical Control Board turns OFF the
relay to shut down the power supply to the Heater Lamp (H1).
C. Thermostat protection
• If neither the soft protection nor hard protection can detect an abnormally high tempera-
ture due to a defective Thermistor (TH1) or other reason, the Thermostat (TS1) operates
at the specified temperature. This shuts down the power supply to the Heater Lamp (H1),
thus forcibly turning it OFF.
5V
Mechanical Control Board
CPU
A/D
Heater Lamp
Thermistor
Heating Roller
Thermostat GND
Hard Protection
Fusing PressureRoller Circuit
Laser Safety Switch
FUSER WDT
Watchdog Circuit RESET
Triac Circuit
Heater Remote
ON/OFF
Power Switch
4139to2097e0
2-55
11.3.4 PPM control

• PPM control is provided to prevent the temperature on edges of the Heating Roller from
increasing during a multi-print cycle using plain paper of a small size.
• The distance between sheets of paper is widened according to the number of printed
pages set to be produced and the paper length. This evens out the temperature of the
Heating Roller and thus stabilizes fusing performance of the printed toner image.
• To perform the PPM control, the number of printed pages per minute is established for
each paper size.
A. Monochrome ordinary environment
Length
210 mm 211 - 216 mm 217 - 257 mm 258 - 297 mm
(8.2”) (8.3” - 8.5”) (8.6” - 10.1”) (10.2” - 11.7”)
92 - 138 mm
14 14 14 14
(3.6” - 5.4”)
139 - 147 mm
18 18 14 14
(5.5” - 5.8”)
148 - 181 mm
Width 19 18 14 14
(5.9” - 7.1”)
182 - 209 mm
20 20 20 14
(7.2” - 8.2”)
210 - 216 mm
20 20 20 20
(8.3” - 8.5”)
B. Monochrome low temperature environment

• The low temperature environment refers to the condition, in which the Temperature/
Humidity Sensor (HS1) detects a temperature of less than 20° C.
Length
210 mm 211 - 216 mm 217 - 257 mm 258 - 297 mm
(8.2”) (8.3” - 8.5”) (8.6” - 10.1”) (10.2” - 11.7”)
92 - 138 mm
12 12 12 12
(3.6” - 5.4”)
139 - 147 mm
15 15 12 12
(5.5” - 5.8”)
148 - 181 mm
Width 16 15 12 12
(5.9” - 7.1”)
182 - 209 mm
17 17 17 12
(7.2” - 8.2”)
210 - 216 mm
20 20 20 20
(8.3” - 8.5”)
2-56
C. Color environment
Length
210 mm 211 - 216 mm 217 - 257 mm 258 - 297 mm
(8.2”) (8.3” - 8.5”) (8.6” - 10.1”) (10.2” - 11.7”)
92 - 138 mm
3 3 3 3
(3.6” - 5.4”)
139 - 147 mm
5 5 3 3
(5.5” - 5.8”)
148 - 181 mm
Width 5 5 3 3
(5.9” - 7.1”)
182 - 209 mm
5 5 5 3
(7.2” - 8.2”)
210 - 216 mm
5 5 5 5
(8.3” - 8.5”)
2-57
Paper exit section magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
12. Paper exit section

12.1 Composition
[1]
4139to1576c0 4139to1577c0
[1]
[2]
4139to1578c0

• Feeds paper out of the machine onto the Paper Exit
[1] Paper Exit Roller Tray.
• Driven by the Fusing Motor (M7)
• Detects a sheet of paper fed from the Heating Roller
[2] Exit Sensor (PC7)
and Fusing Pressure Roller.
2-58
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Paper exit section
12.2 Drive (magicolor 2400W)
[2]
[1]
4139to1579c0
[1] Paper exit roller [2] Fusing Motor (M7)
12.3 Drive (magicolor 2430 DL)
[2]
[1]
4139to1604c0
[1] Paper exit roller [2] Fusing Motor (M7)
2-59
Image stabilization control magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
13. Image stabilization control

13.1 Overview
• To ensure that a stabilized output image is produced at all times, the following image sta-
bilization controls are provided.
Purpose Control Detection

ATVC
To ensure stabilized transfer * Described in the section
Temperature/ humidity Sensor (HS1)
output dealing with the Transfer
Section
AIDC control
• Leak detection control
• AIDC intensity control
• Reflectance measure-
To ensure stabilized image

ment control AIDC Sensor (AIDC)
density; to ensure good tone
• Control of the maximum Temperature/ humidity Sensor (HS1)
reproduction
amount of toner sticking
• Laser intensity adjust-
ment control
• γ correction control
*An explanation is given of the control for each section.
AIDC Sensor
1st Transfer Roller
2nd Transfer Roller
Developing PC Charging
Developing Bias Grid Bias
AIDC Control ATVC
IN
Temperature/ OUT
humidity Sensor 4139to2098e0
2-60
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Image stabilization control
13.2 Operation
13.2.1 Leak detection control
• For the clearance between the Photo Conductor and Developing Roller, an optimum
developing bias voltage is established that does not result in a leak image or uneven
density.
13.2.2 AIDC Sensor LED intensity control
• The following adjustment is made to correct any changes in characteristics occurring due
to change with time and contamination of the AIDC Sensor (AIDC): the intensity of the
LED is adjusted for the surface of the Transfer Belt on which no toner sticks, so that the
output value of the AIDC Sensor (AIDC) becomes constant.
13.2.3 Reflectance measurement control
• The reflectance of the Image Transfer Belt is measured using the ADIC Sensor (AIDC).
One measurement is taken for one complete turn of the Image Transfer Belt.
• The measured value is corrected during the laser intensity adjustment control and γ cor-
rection control.
13.2.4 Control of the maximum amount of toner sticking

• The developing bias setting value is adjusted to keep constant the amount of toner stick-
ing to the surface of the Photo Conductor with reference to the 100% solid image.
13.2.5 Laser intensity adjustment control

• Characteristics of the Photo Conductor, developing, and charging change as affected by
changes with time and in environment. The intensity of the laser light is adjusted so that
fine lines and gradations of a predetermined level are reproduced at all times.
13.2.6 γ correction control
• A gradation pattern is produced on the surface of the Image Transfer Belt. The AIDC
Sensor (AIDC) measures the density of the pattern and sends the measured result to the
controller for gradation adjustment.
2-61
Image stabilization control magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
13.3 Operation timing
Mode Operation Timing

• The environment in which the Power Switch is turned ON is different from the environ-
ment the machine was in when the Power Switch was turned OFF last.
• The environment in which the Energy Saver mode is canceled is different from the envi-
Mode 1 ronment the machine was in when it entered the Energy Saver mode last.
• The Power Switch is turned OFF and ON or the Energy Saver mode is canceled after a
predetermined number of printed pages have been produced.
• A new Drum Cartridge or Toner Cartridge is detected.
• The Power Switch is turned OFF and ON or the Energy Saver mode is canceled after a
Mode 2
predetermined number of printed pages have been produced.
13.4 Operation flow

Mode 1 Mode 2
ATVC control AIDC intensity control
Control of the maximum

Leak detection control
Reflectance
AIDC intensity control
measurement control
Reflectance Laser intensity control

measurement control
Control of the maximum

Laser intensity control
γ correction control
4139to2099e0
2-62
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Other control
14. Other control

14.1 Fan control
14.1.1 Construction
Exhaust
[1]
Suction [2]
Exhaust
Ozone Filter
4139to2100e0

[1] Power Supply Cooling Fan Motor (M4) • Cools the Power Unit (PU) and draws in outside air
• Uses the Ozone Filter that removes ozone from the
[2] Ventilation Fan Motor (M6)
air drawn by this motor to the outside
2-63
Other control magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004
14.1.2 Control
A. Power Supply Cooling Fan Motor
<Full-speed conditions>
• For the predetermined period of time after the Power Switch has been turned ON
• For the specified period of time up to the end of Energy Saver mode
• At the start of a print cycle (full-speed rotation after the lapse of a predetermined period
of time of half-speed rotation). No full-speed rotation is performed if the print cycle is
completed during half-speed rotation.
<Half-speed conditions>
• At the end of a print cycle (half-speed rotation after the lapse of a predetermined period
of time of full-speed rotation)
• Half-speed rotation under any condition other than above
<Stop conditions>
• In Energy Saver mode
• The Power Supply Cooling Fan Motor (M4) develops a malfunction

B. Ventilation Fan Motor
<Full-speed condition>
• While the Main Motor (M1) remains energized
<Stop conditions>
• The lapse of a predetermined period of time after the Main Motor (M1) has been deener-
gized
• Stop under any condition other than above
<Forced stop condition>

• A door is opened, a paper misfeed has occurred, or a malfunction has occurred
2-64
magicolor 2400W/2430 DL Theory of Operation Ver. 2.0 Oct. 2004 Other control
14.2 Temperature/ Humidity Sensor

14.2.1 Composition
[1]
4139to1594c0

• Measures the temperature inside the machine
[1] Temperature/ Humidity Sensor (HS1) • Used for image stabilization control, ATVC, and fus-
ing temperature control
2-65
Lower Feeder Unit
2004.10
Ver. 1.0
Revision mark:
ing page.
NOTE

Lower Feeder Unit Theory of Operation Ver. 1.0 Oct. 2004
CONTENTS
I General
1.1 Type ................................................................................................................... 1-1
1.2 Paper type ......................................................................................................... 1-1
I Outline
1.3 Machine specifications....................................................................................... 1-1
1.4 Operating environment ...................................................................................... 1-1
II Composition/Drive
1. Composition ......................................................................................................... 2-1
2. Drive ..................................................................................................................... 2-2
3. Drive ..................................................................................................................... 2-3
3.1 Conveyance Drive Mechanism .......................................................................... 2-3
3.2 Paper Empty Detection ...................................................................................... 2-4
3.3 Tray Set Detection ............................................................................................. 2-5
i
I Outline
II Composition/Operation Lower Feeder Unit Theory of Operation Ver. 1.0 Oct. 2004
ii
Lower Feeder Unit Theory of Operation Ver. 1.0 Oct. 2004 Product specifications
I General
1.1 Type
Name Add-on 500-sheet paper feed cassette
I General
Type Front-loading type
Installation Desk type
Document Alignment Center
1.2 Paper type
Paper Size A4/Letter

Paper Type • Plain paper: 60 to 90 g/m2 (16 to 24 lb)
• Recycled paper: 60 to 90 g/m2 (16 to 24 lb)
Capacity 500 sheets
1.3 Machine specifications
Power Requirements DC 24 V ± 10 % (supplied from the main unit)

DC 5 V ± 5 %
Max. Power
12 W
Consumption
430 (W) × 500 (D) × 138 (H) mm
Dimensions
16.9" (W) × 19.6" (H) × 5.4" (D)
Weight Approx. 4.6 kg (10.1 lb)
1.4 Operating environment
NOTE
1-1
I General Product specifications Lower Feeder Unit Theory of Operation Ver. 1.0 Oct. 2004
Blank Page
1-2
Lower Feeder Unit Theory of Operation Ver. 1.0 Oct. 2004 Composition
II Composition/Drive
1. Composition
4057to2510c0 4056to2501c0
[1]
[2]
[3]
[4]
[5]
4056to2502c0

[1] Lower Feeder Board (PWB-A PF) • Controls the Lower Feeder Unit.
Lower Feeder Paper Empty Sensor • Detects the level of the paper still available for
[2]
(PC13 PF) use in the Lower Feeder Unit.
[3] Tray Set Detecting Switch (S4 PF) • Detects whether or not Tray 2 is installed.
[4] Pick-up Roller • Takes up and Pick-up paper from the tray.
Lower Feeder Paper Pick-up Solenoid • Transmits drive from the Main Motor to the
[5]
(SL7 PF) Pick-up Roller.
2-1
Drive Lower Feeder Unit Theory of Operation Ver. 1.0 Oct. 2004
2. Drive
4056to2503c0
2-2
Lower Feeder Unit Theory of Operation Ver. 1.0 Oct. 2004 Drive
3. Drive
3.1 Conveyance Drive Mechanism
• The Lower Feeder Unit is not provided with any drive motor. The driving force for paper
feeding and conveyance (drive from M1) is transmitted through a coupling gear from the
printer.
• The paper separation mechanism uses separation claws installed in the unit and elastic-
ity of the paper. It ensures that only one sheet of paper is fed in at time.
• The Lower Feeder Paper Pick-up Solenoid (SL7 PF) is controlled from the printer side
through the Lower Feeder Board (PWB-A PF) mounted in the Lower Feeder Unit.
Coupling gear Lower Feeder Board (PWB-A PF)
Lower Feeder Paper
Empty Sensor (PWB-A PF)
Lower Feeder Paper Pick-up

Solenoid (SL7 PF)
4056to2504e0
2-3
Drive Lower Feeder Unit Theory of Operation Ver. 1.0 Oct. 2004
3.2 Paper Empty Detection

• The Lower Feeder Paper Empty Sensor (PC13 PF) of the Lower Feeder Board (PWB-A
PF) detects a paper empty condition in the Lower Feeder Unit.
• When there is paper loaded in the Lower Feeder Unit, the actuator is raised, which
unblocks the sensor.
• When there is no paper, the actuator drops into the slit in the Paper Lift Plate, thus block-
ing the sensor.
Lower Feeder Board (PWB-A PF)
Lower Feeder Paper

Empty Sensor (PC13 PF)
At paper empty condition Under normal condition 4056to2505e0
2-4
Lower Feeder Unit Theory of Operation Ver. 1.0 Oct. 2004 Drive
3.3 Tray Set Detection

• The Lower Feeder Unit is provided with a Tray Set Detecting Switch (S4 PF) that is
attached with a segment lever.
• When Tray 2 is inserted, the switch actuator on the right-hand side of Tray 2 pushes the
lever. This turns ON the Tray Set Detecting Switch (S4 PF).
Lever
Tray Set Detecting Switch (S4 PF)
OFF
ON
Switch Actuator
Tray 2
4056to2506e0
2-5
II Composition/Operation Drive Lower Feeder Unit Theory of Operation Ver. 1.0 Oct. 2004
Blank Page
2-6
Duplex Unit
2004.10
Ver. 1.0
Revision mark:
ing page.
NOTE

Duplex Option Theory of Operation Ver. 1.0 Oct. 2004
CONTENTS
I General
1.1 Type ................................................................................................................... 1-1
1.2 Paper type ......................................................................................................... 1-1
I Outline
1.3 Machine specifications....................................................................................... 1-1
1.4 Operating environment ...................................................................................... 1-1
1. Composition ......................................................................................................... 2-1
2. Drive ..................................................................................................................... 2-2
3. Mechanical operations ......................................................................................... 2-3
3.1 Switchback mechanism ..................................................................................... 2-3
3.1.1 Switchback operation.................................................................................... 2-3
3.1.2 Paper exit roller drive coupling mechanism .................................................. 2-4
3.1.3 Switchback Motor Control............................................................................. 2-4
3.2 Transport and duplex paper take-up mechanism............................................... 2-5
3.2.1 Transport and duplex paper take-up operation ............................................. 2-5
3.2.2 Duplex Unit Transport Motor Control ............................................................ 2-5
3.2.3 Duplex Unit Loop Correction Control ............................................................ 2-5
3.3 2-sided printing method ..................................................................................... 2-6
3.3.1 Operations in 2-sided printing with a single sheet of paper resident
in the system ................................................................................................ 2-6
3.3.2 Operations in 2-sided printing with two sheets of paper resident
in the system ................................................................................................ 2-8
i
I Outline
II Composition/Operation Duplex Option Theory of Operation Ver. 1.0 Oct. 2004
ii
Duplex Option Theory of Operation Ver. 1.0 Oct. 2004 Product specifications
I General
1.1 Type
Name Duplex Option
I General
Type Switchback and Circulating Duplex Unit
Installation Mounted on the right side door of main unit
Reversing System Exit Roller switchback
Conveyance system Rubber roller + driven rolls
Document Alignment Center
1.2 Paper type
Paper Size A4/Letter

Paper Type • Plain paper: 60 to 90 g/m2 (16 to 24 lb)
• Recycled paper: 60 to 90 g/m2 (16 to 24 lb)
1.3 Machine specifications
Power Requirements DC 24 V ± 10 % (supplied from the main unit)

DC 5 V ± 5 % (supplied from the main unit)
Max. Power
42 W
Consumption
370 (W) × 153 (D) × 327 (H) mm
Dimensions
14.6" (W) × 6.0" (D) × 12.9" (H)
Weight Approx. 2.3 kg (5.1 lb)
1.4 Operating environment
NOTE
1-1
I General Product specifications Duplex Option Theory of Operation Ver. 1.0 Oct. 2004
Blank Page
1-2
Duplex Option Theory of Operation Ver. 1.0 Oct. 2004 Composition
1. Composition
4057to2504c0 4057to2500c0
[5]
[4]
[1]
[6]
[11]
[7]
[8]
[10]
[2]
[9]
[2]
[3] 4057to2503c0 4057to2505c0

• Conveys paper in the Duplex Unit.
[1] Duplex Unit Transport Roller 1
• Driven by the Duplex Transport Motor.
[2] Duplex Registration Roller • Starts feeding the paper from the Duplex Unit so
that the paper is correctly synchronized with the
[3] Duplex Unit Transport Roller2 image on the Transfer Belt.
[4] Duplex Cooling Fan Motor (M10 DU) • Cools the inside of the Duplex Unit.
• Conveys the paper into the Duplex Unit.
[5] Duplex Reverse Motor (M9 DU)
• Drives the Paper Exit Roller.
[6] Duolex Transport Motor (M8 DU) • Conveys paper in the Duplex Unit.
• Determines whether the Duplex Door is open or
[7] Duplex Door Sensor (PC11 DU)
closed.
Duplex Registration Solenoid
[8] • Controls drive of the Duplex Registration Roller.
(SL6 DU)
[9] Duplex Paper Loop Sensor (PC10 DU) • Activated to allow a loop to be formed in the paper.
[10] Duplex Board (PWB-A DU) • Controls drive of the Duplex Unit.
[11] Duplex Transport Sensor (PC12 DU) • Detects paper conveyed into the Duplex Unit.
2-1
Drive Duplex Option Theory of Operation Ver. 1.0 Oct. 2004
2. Drive
[1]
[5]
[2]
[4]
[3]
4057to2506c0
[1] Duplex Reverse Motor (M9 DU) [4] Duplex Registration Roller
[2] Duolex Transport Motor (M8 DU) [5] Duplex Unit Transport Roller 1
[3] Duplex Unit Transport Roller 2
2-2
Duplex Option Theory of Operation Ver. 1.0 Oct. 2004 Mechanical operations
3. Mechanical operations
3.1 Switchback mechanism
3.1.1 Switchback operation
• The Paper Exit Roller of the main unit is used to subject the 1-sided print to a switchback
sequence so that the 1-sided print is to be transported through the Duplex Unit.
Feeding the Paper into Duplex Unit
Exit Sensor (PC7)
Paper Exit Roller
4057to2507c0
2-3
Mechanical operations Duplex Option Theory of Operation Ver. 1.0 Oct. 2004
3.1.2 Paper exit roller drive coupling mechanism

• When the Duplex Unit is mounted, the gear assy of the Fusing Unit is raised by the lead-
ing edge of the Duplex Unit lever, thereby disconnecting drive from the machine (Fusing
Roller). The Paper Exit Roller is driven by the Duplex Reverse Motor.
Duplex Reverse Motor (M9 DU)
Fusing Unit Gear Assy
Duplex Unit Lever

4057to2508c0
3.1.3 Switchback Motor Control

• Rotation of the Duplex Reverse Motor (M9 DU) is controlled by the signal output from the
Duplex Board (PWB-A DU).
2-4
3.2 Transport and duplex paper take-up mechanism

3.2.1 Transport and duplex paper take-up operation
• Drive for the Duplex Unit is provided by the Duplex Unit Transport Motor (M8 DU).
Duplex Unit Transport Roller 1 Duplex Unit Trans-

port Motor (M8 DU)
Duplex Registration Roller
Duplex Unit Transport Roller 2
4057to2509c0
3.2.2 Duplex Unit Transport Motor Control

• Rotation of the Duplex Unit Transport Motor is controlled by the signals output from the
Duplex Control Board.
3.2.3 Duplex Unit Loop Correction Control

• A loop correction mechanism is provided to prevent skew from occurring in the second
page.
• The Duplex Registration Solenoid (SL6 DU) is energized after the lapse of a given period
of time after the Duplex Paper Loop Sensor (PC10 DU) has been activated. This drives
the Duplex Registration Roller. When the Duplex Registration Roller is driven, the paper
is conveyed into the machine.
2-5
3.3 2-sided printing method

• The following two types of 2-sided printing methods are available.
2-sided printing with a single sheet of paper resident in the

2-sided printing system
method
2-sided printing with two sheets of paper resident in the
system (When the FD length is no less than 276 mm, no more
than 297 mm).
Automatic 2-sided printing is not effective when the FD length is less than 276 mm.
3.3.1 Operations in 2-sided printing with a single sheet of paper resident in the
system
Operation 1 Paper Exit

• The first sheet of paper is taken up and fed in from the Roller
main unit drawer and the main unit starts the first print
cycle to produce the print image of the second page of the
2
original.
Operation 2
• Immediately before the 1-sided print leaves the Paper Exit
Roller, the direction of rotation of the Paper Exit Roller is 2
reversed and the 1-sided print is transported toward and
into the Duplex Unit.
Operation 3
• The paper conveyed through the Duplex Unit is tempo-
rarily stopped at the Duplex take-up position.
• Any skew in the paper is corrected at the Duplex Unit Tim-
ing Roller before the paper is taken up and fed by the 2
Duplex Unit.
2-6
Operation 4
• The main unit carries out the second print cycle to produce
the print image of the first page of the original on the other
side of the 1-sided print. 1 2
Operation 5
• While feeding the first 2-sided print out of itself, the main
2
unit carries out the first print cycle for the second sheet of
paper to produce the print image of the fourth page of the 1
4
original.
• Steps 2 through 5 are repeated.
• Two A4 originals with a single sheet of paper resident in the system
Exit Sensor (PC7)

Forward Backward Forward
Rotation Rotation Rotation
Duplex Reverse Motor
(M9 DU)
Duolex Transport Motor
(M8 DU)
Duplex Registration Solenoid
(SL6 DU)
Duplex Paper Loop Sensor
(PC10 DU)
4057to2501e0
2-7
3.3.2 Operations in 2-sided printing with two sheets of paper resident in the sys-
tem
Operation 1 Paper Exit

• The first sheet of paper is taken up and fed in from the Roller
main unit drawer and the main unit starts the first print
cycle to produce the print image of the second page of the
original. 2
Operation 2
• Immediately before the first 1-sided print leaves the Paper
Exit Roller, the direction of rotation of the Paper Exit Roller is 2

reversed and the first 1-sided print is transported toward and
into the Duplex Unit.
• At the same time, the second sheet of paper is taken up and
fed into the main unit.
Operation 3
• The main unit carries out the first print cycle for the second
sheet of paper to produce the print image of the fourth page
of the original. 4
• At the same time, the first 1-sided print is transported 2
through the Duplex Unit.
Operation 4
• The main unit produces the print image of the first page of
the original on the first 1-sided print that has been fed
through the Duplex Unit. 1 2
4
• At the same time, the second sheet of paper is subjected to
a switchback sequence at the exit section and fed into the
Duplex Unit.
• At the same time, the third sheet of paper is taken up and 6
2-8
Operation 5
• While feeding the first 2-sided print out, main unit produces
the print image of the 6th page of the original on the third 2
sheet of paper. 1
• The second sheet of paper waits at the Duplex take-up posi-
tion until the third sheet of paper is subjected to a switch- 6
back sequence. 4
Operation 6
• Immediately before the first 1-sided print leaves the Paper
Exit Roller, the direction of rotation of the Paper Exit Roller is 6
reversed and the first 1-sided print for the third sheet is 2
transported toward and into the Duplex Unit. 1
• At the same time, the second sheet of paper is fed into the
main unit again. 4
Operation 7
• The main unit carries out the first print cycle for the second
sheet of paper to produce the print image of the third page
of the original. 2 3 4
• At the same time, the first 1-sided print for the third is trans- 1
ported through the Duplex Unit.
• At the same time, the forth sheet of paper is taken up and 6
Operation 8
• While feeding the second 2-sided print out, main unit pro-
4
duces the print image of the 8th page of the original on the
fourth sheet of paper. 3 2
• The third sheet of paper waits at the Duplex take-up position 1
8
until the fourth sheet of paper is subjected to a switchback
sequence. 6
• Steps 6 through 8 are repeated.
2-9
• 2-sided printing of two A4 originals with two sheets of paper resident in the sys-
tem
Belt Positioning Sensor

(PC4)
Exit Sensor (PC7)

Forward Backward Forward Backward Forward Backward Forward Backward Forward
Duplex Reverse Motor Rotation Rotation Rotation Rotation Rotation Rotation Rotation Rotation Rotation
(M9 DU)
Duolex Transport Motor
(M8 DU)
Duplex Registration
Solenoid (SL6 DU)

Duplex Paper Loop
Sensor (PC10 DU)
4057to2502e0
2-10
magicolor® 2430 DL
magicolor® 2400W
magicolor 2400W
®
magicolor 2430 DL
®
THEORY OF OPERATION
2004.10 Ver.2.0
© 2004 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

Printed in Japan
Use of this manual should be strictly supervised to
4139-7990-11
2004.10
avoid disclosure of confidential information.
0410XXXX Ver. 2.0

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SERVICE MANUAL THEORY OF OPERATION

© 2004 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

SAFETY AND IMPORTANT WARNING ITEMS

DESCRIPTION ITEMS FOR DANGER,

DANGER: Action having a high possibility of suffering death or serious injury

WARNING: Action having a possibility of suffering death or serious injury

CAUTION: Action having a possibility of suffering a slight wound, medium

:Precaution when servicing the

:Prohibition when servicing the

:Direction when servicing the

• Using any fuse or thermostat not specified by KMBT.

• Disabling fuse functions or bridging fuse terminals with

• Disabling relay functions (such as wedging paper between

• Disabling safety functions (interlocks, safety circuits, etc.)

• Making any modification to the product unless instructed

• Using parts not specified by KMBT

[2] POWER PLUG SELECTION

Power Cord Set or Power Plug

• Attach power plug which meets the following criteria:

• Conductors in the power cable must be connected to ter-

[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

Connection to Power Supply

• Make sure the power cord is plugged in the wall outlet

• Check whether the product is grounded properly.

Power Plug and Cord

• Check whether the power cord is not stepped on or

• Check whether the power cord is damaged. Check

• Check whether dust is collected around the power plug

• When an extension cord is required, use a specified one.

Prohibited Installation Places

• Do not place the product in a place exposed to water such

When not Using the Product for a long time

Inspection before Servicing

• Before conducting an inspection, be sure to disconnect

Work Performed with the Product Powered On

• Do not allow any metal parts such as clips, staples, and

• Check wiring for squeezing and any other damage.

• Check high-voltage cables and sheaths for any damage.

• Before disassembling or adjusting the write unit (P/H unit)

• Do not remove the cover of the write unit. Do not supply

• When replacing a lithium battery, replace it with a new lith-

• After replacing a part to which AC voltage is applied (e.g.,

• Check the interlock switch and actuator for loosening and

• Never throw the used cartridge and toner into fire.

Handling of Service Materials

• Do not replace the cover or turn the product ON before

Handling of Service Materials

• When using any solvent, ventilate the room well.

[4] Laser Safety

4.1 Internal Laser Radiation

This figure shows

4.2 Laser Safety Label

4.3 Laser Caution Label

4.4 PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT

WARNING INDICATIONS ON THE MACHINE

2004/10 2.0 1 Adding the descriptions of magicolor 2430 DL

5.2.2 Laser exposure process ............................................................................. 2-11

6.2.1 Developing drive control ............................................................................. 2-16

7. Image Transfer Section ...................................................................................... 2-24